541090 EN 04/05
Intended use
The Festo Didactic Learning System has been developed and produced solely for vocational and further training in the field of automation and technology. The training company and/or instructor needs to ensure that trainees observe the safety precautions specified in this workbook.. Festo Didactic hereby disclaims any legal liability for damages or injury to trainees, the training company and/or other parties, which may occur during the use/application of this equipment set other than in a training situation and unless such damages are caused by intention or gross negligence on the part of Festo Didactic.
Order No.: Status: Authors: Editor: Graphics: Layout:
541090 04/2005 M. Pany, S. Scharf Frank Ebel Doris Schwarzenberger 09/2005
© Festo Didactic GmbH & Co. KG, 73770 Denkendorf, Germany, 2005 Internet: www.festo-didactic.com e-mail:
[email protected]
The copying, distribution and utilisation of this document as well as the communication of its contents to others without express authorisation is prohibited. Offenders will be held liable for the payment of damages. All rights reserved, in particular the right to carry out patent, utility model or ornamental design registration. Parts of this documentation may be copied by the authorised user exclusively for training purposes.
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© Festo Didactic GmbH & Co. KG • 541090
Contents
Preface ______________________________________________________________ 5 Introduction__________________________________________________________ 7 Notes on safety and operation ___________________________________________ 9 Technology package for electropneumatics (TP200) ________________________ 11 Training aims of Basic Level (TP201) _____________________________________ 13 Allocation of training aims and exercises _________________________________ 15 Equipment set – Basic Level (TP201) _____________________________________ 17 Allocation of equipment and exercises ___________________________________ 21 Methodological help for the trainer ______________________________________ 23 Methodological structure of the exercises_________________________________ 25 Designation of equipment _____________________________________________ 26 Contents of the CD-ROM _______________________________________________ 27 Equipment set – Advanced Level (TP202) _________________________________ 29 Training aims – Advanced Level (TP202) __________________________________ 30
Part A – Exercises Exercise 1: Realising a sorting device ____________________________________A-3 Exercise 2: Realising a shut-off device___________________________________A-15 Exercise 3: Realising a lid press ________________________________________A-25 Exercise 4: Realising the operation of a hinged lid _________________________A-35 Exercise 5: Realising a diverting device __________________________________A-43 Exercise 6: Actuation of a stacking magazine _____________________________A-53 Exercise 7: Sorting of packages ________________________________________A-65 Exercise 8: Actuation of a sliding platform _______________________________A-73 Exercise 9: Expanding a diverting device _________________________________A-81 Exercise 10: Designing a stamping device________________________________A-91 Exercise 11: Realising a pallet loading station __________________________ A-101 Exercise 12: Eliminating a fault on the pallet loading station_______________ A-107
© Festo Didactic GmbH & Co. KG • 541090
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Contents
Part B – Fundamentals
Part C – Solutions Exercise 1: Realising of a sorting device __________________________________C-3 Exercise 2: Realising a shut-off device___________________________________C-15 Exercise 3: Realising a lid press ________________________________________C-23 Exercise 4: Realising the operation of a hinged lid _________________________C-33 Exercise 5: Realising a diverting device __________________________________C-41 Exercise 6: Actuation of a stacking magazine _____________________________C-49 Exercise 7: Sorting of packages ________________________________________C-59 Exercise 8: Actuation of a sliding platform _______________________________C-67 Exercise 9: Expanding a diverting device _________________________________C-75 Exercise 10: Designing a stamping device________________________________C-85 Exercise 11: Realising a pallet loading station ____________________________C-95 Exercise 12: Eliminating a fault on the pallet loading station _______________C-101
Part D – Appendix Organiser __________________________________________________________ D-2 Assembly technology ________________________________________________ D-3 Plastic tubing_______________________________________________________ D-4 Data sheets
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© Festo Didactic GmbH & Co. KG • 541090
Preface
Festo Didactic’s Learning System for Automation and Technology is orientated towards different training and vocational requirements and is therefore structured into the following training packages: • Basic packages to provide technology-spanning basic knowledge • Technology packages to address the major subjects of open and closed-loop technology • Function packages to explain the basic functions of automated systems • Application packages to facilitate vocational and further training based on actual industrial applications The technology packages deal with the following technologies: Pneumatics, electropneumatics, programmable logic controllers, automation using a personal computer, hydraulics, electrohydraulics, proportional hydraulics and handling technology.
© Festo Didactic GmbH & Co. KG • 541090
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Preface
The modular design of the learning system enables applications beyond the limits of the individual packages. For example, to facilitate PLC actuation of pneumatic, hydraulic and electrical drives. All the training packages are of identical structure: • Hardware • Teachware • Software • Seminars The hardware consists of didactically designed industrial components and systems. The didactic, methodological design of the Teachware is harmonised with the training hardware and comprises: • Textbooks (with exercises and examples) • Workbooks (with practical exercises, additional information, solutions and data sheets) • Overhead transparencies and videos (to create an interesting and lively training environment) Tuition and training media are available in several languages and are suitable for use both in the classroom and for self-tuition. Software is available in the form of computer training programs and programming software for programmable logic controllers. A comprehensive range of seminars dealing with the topics of the technology packages completes the range of vocational and further training available.
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© Festo Didactic GmbH & Co. KG • 541090
Introduction
This workbook is a component part of the Learning System for Automation and Technology of Festo Didactic GmbH & Co. KG. This system provides a solid basis for practice-oriented vocational and further training. Technology package TP200 is comprised exclusively of electropneumatic control systems. Basic Level TP201 is suitable for basic training in electropneumatic control technology and provides knowledge regarding the physical fundamentals of electropneumatics and the function and use of electropneumatic equipment. The equipment set enables you to construct simple electropneumatic control systems. Advanced Level TP202 focuses on further training in electropneumatic control technology. The two equipment sets enable you to construct complex combinational circuits with logic operations of input and output signals and program controls. Prerequisite for the assembly of control systems is a fixed workstation using a Festo Didactic profile plate, consisting of 14 parallel T-slots with 50 mm spacing. A shortcircuit protected power supply unit (input: 230 V, 50 Hz, output: 24 V, max. 5 A) is used for DC voltage supply. A mobile, silenced compressor (230 V, maximum 8 bar = 800 kPa) can be used for compressed air supply. Working pressure must not exceed a maximum of p = 6 bar = 600 kPa. Optimum operational reliability is achieved if the control system is operated unlubricated at a working pressure of p = 5 bar = 500 kPa. The equipment set of Basic Level TP201 is used to construct all of the complete control systems of the 12 problem definitions. The theoretical fundamentals to help you understand this collection of exercises can be found in the textbook • Electropneumatics Also available are data sheets in respect of the individual devices (cylinders, valves, measuring devices, etc.).
© Festo Didactic GmbH & Co. KG • 541090
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Introduction
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© Festo Didactic GmbH & Co. KG • 541090
Notes on safety and operation
The following advice should be observed in the interest of your own safety: • Pressurised air lines that become detached can cause accidents. Switch off supply immediately. • Do not switch on compressed air until tubing is securely connected. • Caution! Cylinders may advance automatically as soon as the compressed air is switched on. • Do not operate an electrical limit switch manually during fault finding (use a tool). • Observe general safety regulations. • With electrical limit switches you need to distinguish between two designs – Actuation from the left – Actuation from the right. • At high piston speeds, limit switches must be approached only in the designated direction of the trip cam of the cylinder. Limit switches must not be actuated from the front. • Do not exceed the permissible working pressure (see data sheets). • Only use extra-low voltage ≤ 24 V DC. • All components are equipped with 4 mm safety sockets, i.e. jack plugs. Only use cables with jack plugs for the electrical connections. • Pneumatic circuit assembly: Connect devices using the silver-metallic plastic tubing of 4mm outer diameter, plugging the tubing into the push-in fitting up to the stop; no need for securing! • Releasing of push-in fitting: The tubing can be released by pressing down the releasing ring (disconnection under pressure is not possible!) • Switch off compressed air supply and power supply prior to dismantling the circuit.
© Festo Didactic GmbH & Co. KG • 541090
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Notes on safety and operation
• The mounting plates of the devices are equipped with mounting variants A to D: Variant A, latching system For lightweight non loadable devices (e.g. directional control valves). Simply clip the device into the slot in the profile plate. Devices can be released by pressing the blue lever. Variant B, rotary system Medium weight loadable devices (e.g. actuators). These devices are clamped onto the profile plate by means of T-head bolts. Clamping and releasing is effected by means of the blue knurled nut. Variant C, screw system For heavy loadable devices rarely removed from the profile plate (e.g. Start-up valve with filter control valve). These devices are mounted by means of socket head screws and T-head bolts. Variant D, plug-in system Lightweight non loadable devices with locking pins (e.g. indicating devices). These devices are attached by means of plug-in adapters. • The data for the individual devices, as specified in the data sheets in Part D, must be observed.
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© Festo Didactic GmbH & Co. KG • 541090
Technology package for electropneumatics (TP200)
The technology package TP200 consists of numerous individual training media as well as seminars. The subject matter of this package is exclusively electropneumatic control systems. Individual components from the technology package TP200 may also form a component part of other packages.
Important elements of TP200
• • • • • •
Fixed workstation with Festo Didactic profile plate Compressor (230 V, 0.55 kW, maximum 8 bar = 800 kPa ) Equipment sets or individual components Optional training aids Practical training models Complete laboratory setups
Training documentation Textbooks
Basic Level TP201 Fundamentals of pneumatic control technology Maintenance of pneumatic devices and systems
Workbooks
Basic Lvel TP201 Advanced Level TP202
Optional Teachware
Sets of overhead transparencies and overhead projector Magnetic symbols, drawing template WBT Fluid Studio Electropneumatics Cutaway model sets 1 + 2 with storage case ® Simulation software FluidSIM Pneumatic
© Festo Didactic GmbH & Co. KG • 541090
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Technology package for electropneumatics (TP200)
Seminars P111
Fundamentals of pneumatics and electropneumatics
P121
Maintenance of and fault finding on pneumatic and electropneumatic systems
IW-PEP
Maintenance and servicing in control technology– pneumatic and electropneumatic control systems
EP-AL
Electropneumatics for vocational training
Details of venues, dates and prices can be found in the current seminar planner. Information regarding further training media is available in our catalogues and on the Internet. The Learning System for Automation and Technology is continually updated and expanded. The sets of overhead transparencies, films, CD-ROMs and DVDs as well as technical books are available in several languages.
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© Festo Didactic GmbH & Co. KG • 541090
Training aims of Basic Level (TP201)
• To familiarise yourself with the design and mode of operation of a single-acting cylinder. • To familiarise yourself with the design and mode of operation of a double-acting cylinder. • To be able to calculate piston forces according to specified values. • To familiarise yourself with the design and mode of operation of a 3/2-way solenoid valve. • To familiarise yourself with the design and mode of operation of a double solenoid valve. • To be able to select solenoid valves according to requirements. • To be able to identify and draw the various types of actuation of directional control valves. • To be able to convert solenoid valves. • To be able to explain and design an example of direct actuation. • To be able to explain and design an example of indirect actuation. • To familiarise yourself with logic functions and to design these. • To familiarise yourself with different types of end position control and to be able to select a suitable type. • To be able to calculate electrical characteristic values. • To familiarise yourself with latching circuits with different characteristics. • To be able to explain and design an electrical latching circuit with dominant switch-off signal. • To be able to design a pressure-dependent control system. • To familiarise yourself with the design and mode of operation of magnetic proximity sensors. • To familiarise yourself with displacement-step diagrams and to be able to design these for specified problem definitions. • To be able to realise a sequence control using two cylinders. • To be able to identify and eliminate errors in simple electropneumatic control systems.
© Festo Didactic GmbH & Co. KG • 541090
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Training aims of Basic Level (TP201)
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© Festo Didactic GmbH & Co. KG • 541090
Allocation of training aims and exercises
Exercise
1
2
3
•
•
4
5
6
7
8
9
10
11
12
Training aims To familiarise yourself with the design
•
and mode of operation of a singleacting cylinder. To familiarise yourself with the design
•
and mode of operation of a doubleacting cylinder. To be able to calculate piston forces according to specified values. To familiarise yourself with the design
•
•
and mode of operation of a 3/2-way solenoid valve. To familiarise yourself with the design
•
•
and mode of operation of a double solenoid valve. To be able to select a solenoid valve according to requirements. To be able to identifiy and draw the
•
•
various types of actuation of directional control valves. To be able to convert solenoid valves. To be able to explain and design an example of direct actuation. To be able to explain and design an example of indirect actuation.
• •
•
•
•
To familiarise yourself with different
•
•
•
types of end position control and to be able to select a suitable type. To familiarise yourself with logic
•
•
functions and to be able to design these. To be able to calculate electrical characteristic values
© Festo Didactic GmbH & Co. KG • 541090
•
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Allocation of training aims and exercises
Exercise
1
2
3
4
5
6
7
8
9
10
11
12
Training aims To familiarise yourself with latching circuits with different characteristics.
•
To be able to explain and design an
•
•
electrical latching circuit with dominant switch-off signal. To be able to design a pressuredependent control system.
•
To familiarise yourself with the mode
•
of operation of magnetic proximity sensors. To familiarise yourself with
•
displacement step diagrams and to be able to create these for specified problem definitions. To be able to realise a sequence control using two cylinders. To be able to detect and eliminate
•
•
errors in simple electropneumatic control systems.
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© Festo Didactic GmbH & Co. KG • 541090
Equipment set – Basic Level (TP201)
This equipment set has been compiled for basic training in electropneumatic control technology. It contains all the components required to meet the specifed training aims and can be expanded in any way with other equipment sets. The profile plate and a compressed air supply are required in addition. Equipment set – Basic Level (TP201 Order No.: 540712)
Description
Order No.
Quantity
2 x 3/2-way solenoid valve, normally closed
539776
1
5/2-way double solenoid valve
539778
2
5/2-way solenoid valve
539777
1
Blanking plug
153267
10
Double-acting cylinder
152888
2
Limit switch, electrical, actuated from the left
183322
1
Limit switch, electrical, actuated from the right
183322
1
Manifold
152896
1
One-way flow control valve
539773
4
Plastic tubing 4 x 0.75, 10 m
151496
2
Pressure sensor
539757
1
Proximity sensor, electronic
540695
2
Proximity sensor, optical
178577
1
Push-in sleeve
153251
10
Push-in T-connector
153128
20
Relay, 3-off
162241
2
Signal input, electrical
162242
1
Single-acting cylinder
152887
1
Start-up valve with filter control valve
540691
1
© Festo Didactic GmbH & Co. KG • 541090
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Equipment set – Basic Level (TP201)
Equipment set symbols
Description
Symbol
Relay, 3-off
A1
A2 A1
A2 A1
A2 Signal input, electrical
12 14
22 24
32 34
42 44
11
21
31
41
12 14
22 24
32 34
42 44
11
21
31
41
12 14
22 24
32 34
42 44
11
21
31
41
13
23
31
41
14
24
32
42
13
23
31
41
14
24
32
42
13
23
31
41
14
24
32
42
3/2-way solenoid valve, normally closed
2 1M1
1
3
1M1
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© Festo Didactic GmbH & Co. KG • 541090
Equipment set – Basic Level (TP201)
Description
Symbol
5/2-way solenoid valve
4
2
1M1 5
1
3
1M1
5/2-way double solenoid valve
4
2
1M1
1M2 5
1M1
1
3
1M2
Proximity sensor, electronic
Pressure sensor
p
Proximity sensor, optical
Limit switch, electrical
4
2
1
One-way flow control valve
© Festo Didactic GmbH & Co. KG • 541090
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2
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Equipment set – Basic Level (TP201)
Description
Symbol
Single-acting cylinder
Double-acting cylinder
Start-up valve with filter control valve
1 2
3
Manifold
Connection elements
20
© Festo Didactic GmbH & Co. KG • 541090
Allocation of equipment and exercises
Exercise
1
2
3
4
5
6
7
8
9
10
11
12
1
1
Equipment Cylinder, single-acting
1
Cylinder, double-acting One-way flow control valve
1
3/2-way double solenoid valve, normally closed
1
5/2-way solenoid valve
1 1
1
2
2
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
3
3
1
1
1
1
(1)
1
1
1
5/2-way double solenoid valve
1 1
1
1
1
Pressure sensor
1
Limit switch, electrical
1
2
Proximity sensor, normally open conact Pushbutton, electrical, normally open contact
1
1
1
1
2
2
1
1
Pushbutton, electrical, normally
2
2
2
2
1
1
1
1
1
1
1
closed button Relay
1
1
2
2
3
1
3
3
3
3
Manifold
1
1
1
1
1
1
1
1
1
1
1
1
Start-up valve with filter control valve
1
1
1
1
1
1
1
1
1
1
1
1
Power supply unit 24 V DC
1
1
1
1
1
1
1
1
1
1
1
1
© Festo Didactic GmbH & Co. KG • 541090
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Allocation of equipment and exercises
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© Festo Didactic GmbH & Co. KG • 541090
Methodological help for the trainer
• Training aims The overall aim of this collection of exercises is the systematic design of circuit diagrams and practical assembly of a control system on a profile plate. This direct interaction of theory and practice ensures quick progress with learning. The detailed training aims are documented in the table. Actual individual training aims are allocated to each problem and major training aims are shown in brackets. • Time required The time required to work through a problem depends on the trainee’s prior knowledge. Skilled workers in the engineering and electrical fields require approximately 2 weeks. Technicians or engineers require approximately 1 week. • Components of the equipment set The book of exercises and equipment set are harmonised. For all 18 exercises you only require the components of the equipment set of Basic Level TP201. Each of the Basic Level exercises can be assembled on a profile plate. • Representation Abbreviated notation and motion diagrams are used for the representation of motion sequences and switching statuses.
© Festo Didactic GmbH & Co. KG • 541090
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Methodological help for the trainer
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© Festo Didactic GmbH & Co. KG • 541090
Methodological structure of the exercises
All 12 exercises in Part A are of identical methodological structure. The exercises are divided into: • Title • Training aims • Problem definition • Parameters as well as • Project task • Positional sketch • Worksheets The proposed solutions in Part C are divided into: • Circuit diagram • Solution description as well as • Circuit assembly • Equipment list
© Festo Didactic GmbH & Co. KG • 541090
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Designation of equipment
The designation of components in the circuit diagrams is effected in accordance with the DIN-ISO 1219-2 standard. All components of a circuit have the same main code number. Letters are assigned depending on components. Several components within a circuit are numbered consecutively. The designation of pressure ports is P and these are separately consecutively numbered. Drives: Valves: Sensors: Signal input: Accessories: Pressure strings:
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1A1, 2A1, 2A2, ... 1V1, 1V2, 1V3, 2V1, 2V2, 3V1, ... 1B1, 1B2, ... 1S1, 1S2, ... 0Z1, 0Z2, 1Z1, ... P1, P2, ...
© Festo Didactic GmbH & Co. KG • 541090
Contents of the CD-ROM
The CD-ROM supplied provides you with additional media. The contents of Part A – Exercises and Part C – Solutions are stored in the form of pdf files. The structure of the CD-ROM is as follows: • Operating instructions • Data sheets • Demo • Festo catalogue • FluidSIM® circuit diagrams • Industrial applications • Presentations • Product information • Videos
Operating instructions
Operating instructions are available for the various pieces of equipment of the technology package to assist you in the use and commissioning of the equipment.
Data sheets
The data sheets for the equipment of the technology package are available in the form of pdf files.
Demo
A demo version of the software package FluidSIM® Pneumatic is stored on the CDROM. This version is suitable for the testing of the control systems developed.
Festo catalogue
Pages from the Festo AG & Co. KG catalogue are provided for selected pieces of equipment. The representation and description of equipment in this form is intended to illustrate how such equipment is represented in an industrial catalogue. You will also find additional information here regarding the equipment.
FluidSIM® circuit diagrams
FluidSIM® circuit diagrams are stored in this directory for all of the 12 exercises in the technology package.
© Festo Didactic GmbH & Co. KG • 541090
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Contents of the CD-ROM
Industrial applications
Photos and pictures are provided of industrial applications to enable you to illustrate your own problem definitions. These can also be added to project presentations.
Presentations
Brief presentations are stored in this directory regarding the equipment of this technology package. These presentations can for instance be used to create project presentations.
Product information
This directory provides you with the product information and data sheets of Festo AG & Co. KG regarding the equipment of the technology package and is intended to explain what information and data are provided for an industrial component.
Videos
A number of videos of industrial applications complete the media for the training package. Short sequences are shown of practice-related applications.
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© Festo Didactic GmbH & Co. KG • 541090
Equipment set – Advanced Level (TP202)
This Advanced Level equipment set has been compiled for further training in pneumatic control technology. The two equipment sets (TP201 and TP202) comprise the components required for the specified training aims and can expanded in any way with other equipments sets of the Learning System for Automation and Technology. Equipment set – Advanced Level (TP202 Order No.: 540713)
Description
Order No.
Quantity
Relay, 3 off
162241
2
Signal input, electrical
162242
1
Time relay, 2 off
162243
1
Predetermining counter
162355
1
Proximity sensor, inductive
178574
1
Proximity sensor, capacitive
178575
1
EMERGENCY-STOP button
183347
1
Valve terminal with 4 valve slices (MMJJ)
540696
1
Non-return valve, piloted
540715
2
© Festo Didactic GmbH & Co. KG • 541090
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Training aims of Advanced Level (TP202)
• To describe the design and use of valve terminals • To solve sequence controls with signal overlap – solution according to group method • To solve sequence controls with signal overlap – solution with sequence chain using spring-return valves • To solve sequence control with signal overlap – solution with sequence chain using double solenoid valves (with control step) • To be able to describe and configure modes of operation (single cycle, continuous cycle, , ...) • To describe the function and use of a predetermining counter • To explain and realise an EMERGENCY-STOP FUNCTION using spring-return valves • To realise special EMERGENCY-STOP conditions: Actuators must stop during EMERGENCY-STOP • To explain the function and use of a 5/3-way solenoid valve • To describe and configure the Reset mode of operation • To carry out fault finding in complex electropneumatic circuits
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© Festo Didactic GmbH & Co. KG • 541090
Contents
Part A – Exercises
Exercise 1: Realising a sorting device ____________________________________A-3 Exercise 2: Realising a shut-off device___________________________________A-15 Exercise 3: Realising a lid press ________________________________________A-25 Exercise 4: Realising the operation of a hinged lid _________________________A-35 Exercise 5: Realising a diverting device __________________________________A-43 Exercise 6: Actuation of a stacking magazine _____________________________A-53 Exercise 7: Sorting of packages ________________________________________A-65 Exercise 8: Actuation of a sliding platform _______________________________A-73 Exercise 9: Expanding a diverting device _________________________________A-81 Exercise 10: Designing a stamping device________________________________A-91 Exercise 11: Realising a pallet loading station __________________________ A-101 Exercise 12: Eliminating a fault on the pallet loading station_______________ A-107
© Festo Didactic GmbH & Co. KG • 541090
A-1
Contents
A-2
© Festo Didactic GmbH & Co. KG • 541090
Exercise 1: Realising a sorting device
Training aims
• To familiarise yourself with the design and mode of operation of a single-acting cylinder. • To familiarise yourself with the design and mode of operation of a 3/2-way solenoid valve. • To be able to identify and draw various types of actuation of directional control valves. • To be able to explain and design an example of direct actuation.
Problem definition
A sorting device is to be used to sort water samples according to the size of the sample bottle. Design a control system whereby this process can be carried out.
Parameters
• A single-acting cylinder is to be used. • The control of the cylinder is to be effected by means of a pushbutton. • In the event of a power failure the cylinder piston rod is to return into the retracted end position.
Project task
1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Draw the pneumatic and electrical circuit diagram. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
© Festo Didactic GmbH & Co. KG • 541090
A-3
Exercise 1: Realising a sorting device
Positional sketch
Sorting device
1. Pressing of a pushbutton causes the piston rod of a single-acting cylinder to push the sample bottle off the conveyor. 2. When the pushbutton is released, the piston rod is to return into the retracted end position.
A-4
© Festo Didactic GmbH & Co. KG • 541090
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device Name:
Date:
Fundamentals: Function of pneumatic working components
Sheet 1 of 7
Pneumatic working components can be divided into two groups: • Working components using linear movement • Working components using rotary movement – Describe the function of the working components shown. Symbol 1
Symbol 2
Symbol 3
Description of function Symbol 1:
Symbol 2:
Symbol 3:
© Festo Didactic GmbH & Co. KG • 541090
A-5
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device Name:
Date:
Fundamentals: Completing solenoid valve symbols
Sheet 2 of 7
– Complete the individual symbols with the help of the corresponding component descriptions. Description
Symbol
Directly actuated 3/2-way
2
solenoid valve, normally open, with manual override, with spring return
1
3
Pilot actuated 3/2-way solenoid
2
valve, normally closed, with manual override, with spring return
A-6
1
3
© Festo Didactic GmbH & Co. KG • 541090
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device Name:
Date:
Fundamentals: Normal positions of directional control valves
Sheet 3 of 7
An electrically actuated 3/2-way solenoid valve has two switching positions. It can be in the normal position (unactuated) or in the switching position (actuated). In the normal position the valve can be open or closed. – Describe the effects on the motion sequence of the following application arising as a result of the different normal positions. The single-acting cylinder shown is controlled by an electrically actuated 3/2-way solenoid valve. 2 1M1
Description: Normal position closed
© Festo Didactic GmbH & Co. KG • 541090
1
2
3
1M1
1
3
Description: Normal position open
A-7
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device Name:
Date:
Fundamentals: Direct and indirect actuation
Sheet 4 of 7
An electrically actuated solenoid valve can be actuated either directly or indirectly. – Describe the difference with the help of the following application: Electrical actuation of a spring-returned 3/2-way solenoid valve using a pushbutton. Description: Direct actuation
A-8
Description: Indirect actuation
© Festo Didactic GmbH & Co. KG • 541090
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device Name:
Date:
Design and function of an electrical switch
Sheet 5 of 7
Switches are basically divided into pushbutton and control switch designs and perform the function of a normally open or normally closed contact or changeover switch. – Describe the design and function of the switches shown. Symbol 1
Symbol 2
3 4
Symbol 3
1
2 2
4 1
Description: Design/Function
© Festo Didactic GmbH & Co. KG • 541090
A-9
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device Name:
Date:
Fundamentals: Mode of operation of different valve types
Sheet 6 of 7
Electrically actuated directional control valves are switches with the help of solenoids. Basically, these can be divided into two groups: • Spring-return solenoid valves • Double solenoid valves – Describe the differences between the two groups with regard to function and behaviour in the event of power failure. Valve type
Mode of operation
Spring-return valve
Double solenoid valve
A-10
© Festo Didactic GmbH & Co. KG • 541090
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device Name:
Date:
Fundamentals: Port designations of valves
Sheet 7 of 7
In order to prevent incorrect tubing up of directional control valves, the valve ports (working and pilot lines) are identified in accordance with ISO 5599, both on the valve itself and in the circuit diagram. – Describe the meaning and function of the designations below. Designation
Meaning, function
3
12
10
© Festo Didactic GmbH & Co. KG • 541090
A-11
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device Name:
Date:
Completing the pneumatic and electrical circuit diagram
Sheet 1 of 1
– Complete the pneumatic and electrical circuit diagram for the sorting device.
2
1
3
Pneumatic circuit diagram +24 V
1
0V
Electrical circuit diagram
A-12
© Festo Didactic GmbH & Co. KG • 541090
Exercise 1: Realising a sorting device
Exercise 1: Realising the operation of a sorting device Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Compile the equipment list by entering the required equipment in the table below. Quantity
Description
Equipment list
© Festo Didactic GmbH & Co. KG • 541090
A-13
Exercise 1: Realising a sorting device
A-14
© Festo Didactic GmbH & Co. KG • 541090
Exercise 2: Realising a shut-off device
Training aims
• To familiarise yourself with the design and mode of operation of a double-acting cylinder. • To be able to explain and design an example of direct actuation.
Problem definition
In a water treatment system numerous pipes need to be opened or and closed by means of shut-off devices. A test setup is to be used to find a possible means of actuating the shut-off valve.
Parameters
• A double-acting cylinder is to be used. • The cylinder control is to be effected by means of a pushbutton. • In the event of power failure the cylinder piston rod is to return into the retracted end position.
Project task
1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
© Festo Didactic GmbH & Co. KG • 541090
A-15
Exercise 2: Realising a shut-off device
Positional sketch
Shut-off device
1. Pressing of a pushbutton is to cause the valve to open the slide 2. Releasing of the pushbutton is to cause the slide to close.
A-16
© Festo Didactic GmbH & Co. KG • 541090
Exercise 2: Realising a shut-off device
Exercise 2: Realising a shut-off device Name:
Date:
Fundamentals: Comparison of directly actuated and pilot actuated valves
Sheet 1 of 5
Differentiation is made between directly actuated and pilot actuated solenoid valves with regard to the type of actuation of the valve piston. – Compare these two valve types and describe the respective advantages and disadvantages. Directly actuated valve
© Festo Didactic GmbH & Co. KG • 541090
Pilot actuated valve
A-17
Exercise 2: Realising a shut-off device
Exercise 2: Realising a shut-off device Name:
Date:
Port designations of valves
Sheet 2 of 5
In order to prevent incorrect tubing up of directional control valves, valve ports (working and pilot lines) are identified in accordance with ISO 5599-3, both on the valve itself and in the circuit diagram. – Describe the meaning and function of the designations below. Designation
Meaning, function
4
14
82/84
A-18
© Festo Didactic GmbH & Co. KG • 541090
Exercise 2: Realising a shut-off device
Exercise 2: Realising a shut-off device Name:
Date:
Fundamentals: Mode of operation of a solenoid valve
Sheet 3 of 5
A valve symbol provides information regarding the function of the valve, i.e. the number of ports, switching positions and type of actuation, but not about the constructional design. – Describe the mode of operation of the directional control valve shown. 4
2
1M1 5
1
3
Description: Mode of operation of a directional control valve
© Festo Didactic GmbH & Co. KG • 541090
A-19
Exercise 2: Realising a shut-off device
Exercise 2: Realising a shut-off device Name:
Date:
Fundamentals: IP classification
Sheet 4 of 5
Depending on the installation and ambient conditions, electrical equipment is protected by means of a housing or cover. The required protection class against dust, humidity and foreign objects is to be identified. The classification IP 65 is shown on a valve – Describe the meaning of this classification. Description of IP 65 classification
A-20
© Festo Didactic GmbH & Co. KG • 541090
Exercise 2: Realising a shut-off device
Exercise 2: Realising a shut-off device Name:
Date:
Fundamentals: Symbols of pneumatic cylinders
Sheet 5 of 5
Piston rod cylinders with linear action can be divided into two groups: • Single-acting cylinders • Double-acting cylinders – Describe the meaning of the cylinder symbol shown. Symbol 1
Symbol 2
Description of symbolic representation
© Festo Didactic GmbH & Co. KG • 541090
A-21
Exercise 2: Realising a shut-off device
Exercise 2: Realising a shut-off device Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 1 of 1
– Complete the pneumatic and electrical circuit diagrams for the sorting device.
4
5
2
1
3
Pneumatic circuit diagram +24 V
1
0V
Electrical circuit diagram
A-22
© Festo Didactic GmbH & Co. KG • 541090
Exercise 2: Realising a shut-off device
Exercise 2: Realising a shut-off device Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Compile the equipment list by entering the required equipment in the table below. Quantity
Description
Equipment list
© Festo Didactic GmbH & Co. KG • 541090
A-23
Exercise 2: Realising a shut-off device
A-24
© Festo Didactic GmbH & Co. KG • 541090
Exercise 3: Realising a lid press
Training aims
• To familiarise yourself with the design and mode of operation of a double-acting cylinder. • To be able to explain and design an example of indirect actuation.
Problem definition
In a filling plant, wall or ceiling paints are filled into plastic pots. Once filled, slip-lids are to be pressed onto the plastic pots.
Parameters
• A double-acting cylinder is to be used. • The cylinder control is to be effected indirectly and by means of a pushbutton. In the event of power failure the cylinder piston rod is to return into the retracted end position.
Project task
1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
© Festo Didactic GmbH & Co. KG • 541090
A-25
Exercise 3: Realising a lid press
Positional sketch
Filling of pots of paint
1. Pressing of a pushbutton is to cause the pressing ram to advance and the slip-lid to be pressed on. 2. Once the pushbutton is released, the pressing ram is to be returned into the initial position.
A-26
© Festo Didactic GmbH & Co. KG • 541090
Exercise 3: Realising a lid press
Exercise 3: Realising of a lid press Name:
Date:
Fundamentals: Mode of operation of relays
Sheet 1 of 4
A relay is a remotely controlled electromagnetically actuated switch with several contacts. The main components are: • Coil with core • Winding of coil • Contact set • Return spring • Armature • Terminal lugs
The following illustration shows a sectional representation of a relay. – Allocate the component designations. 2
3
1 4 5
A1 A2
7
© Festo Didactic GmbH & Co. KG • 541090
4 2
1
6
A-27
Exercise 3: Realising a lid press
Exercise 3: Realising a lid press Name:
Date:
Fundamentals: Design and mode of operation of relays
Sheet 2 of 4
– Describe the mode of operation of a relay. Description of mode of operation of a relay
A-28
© Festo Didactic GmbH & Co. KG • 541090
Exercise 3: Realising a lid press
Exercise 3: Realising a lid press Name:
Date:
Fundamentals: Design and mode of operation of relays
Sheet 3 of 4
One or several contacts can be switched by a relay coil. Relays with normally closed, normally open or changeover contact(s) are used depending on the function required. Additional designs of electromagnetically actuated switches are for instance a remanence relay, the time relay with switch-on delay, the time relay with switch-off delay and the contactor. – Describe the design and contact alignment of the relays shown. Description of design/contact alignment
Symbol
A1
A2 A1
A2
© Festo Didactic GmbH & Co. KG • 541090
13
14
23
24
31
41
32
42
12 14
22 24
32 34
42 44
11
21
31
41
A-29
Exercise 3: Realising a lid press
Exercise 3: Realising a lid press Name:
Date:
Fundamentals: Design and mode of operation of relays
Sheet 4 of 4
– List the possible applications of relays in electrical or electropneumatic control systems. Description: Possible applications
A-30
© Festo Didactic GmbH & Co. KG • 541090
Exercise 3: Realising a lid press
Exercise 3: Realising a lid press Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 1 of 2
– Design the pneumatic and electrical circuit diagrams for the lid press.
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
A-31
Exercise 3: Realising a lid press
Exercise 3: Realising a lid press Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 2 of 2
+24 V
1
0V
2
11
12 14
21
22 24
31
32 34
41
42 44
Electrical circuit diagram
A-32
© Festo Didactic GmbH & Co. KG • 541090
Exercise 3: Realising a lid press
Exercise 3: Realising a lid press Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Compile the equipment list by entering the required equipment in the table below. Quantity
Description
Equipment list
© Festo Didactic GmbH & Co. KG • 541090
A-33
Exercise 3: Realising a lid press
A-34
© Festo Didactic GmbH & Co. KG • 541090
Exercise 4: Realising the operation of a hinged lid
Training aims
• To be able to design an example of indirect actuation • To familiarise yourself with logic operations • To be able to select solenoid valve according to requirements
Problem definition
Plastic granulate is to be filled from a storage silo. The silo is to be opened or closed using a hinged lid. The process is to be effected from two points.
Parameters
• A single-acting cylinder is to be used. • The cylinder control is to be indirect and via hand levers. In the event of power failure, the cylinder piston rod is to advance into the forward end position.
Project task
1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
© Festo Didactic GmbH & Co. KG • 541090
A-35
Exercise 4: Realising the operation of a hinged lid
Positional sketch
Filling of plastic granulate
1. Pressing of either one of the pushbuttons is to cause the hinged lid to open and to empty the bulk material from the container. 2. Once the pusbutton is released, the hinged lid closes.
A-36
© Festo Didactic GmbH & Co. KG • 541090
Exercise 4: Realising the operation of a hinged lid
Exercise 4: Realising the operation of a hinged lid Name:
Date:
Fundamentals: Converting solenoid valves
Sheet 1 of 3
In industrial practice, there are numerous different requirements with regard to a valve. If a valve with all the required features is not available, it is often possible to use a valve with a different number of ports. The table below lists a selection of directional control valves frequently in use in industrial applications. – Describe the valve types shown. – Identify all solenoid valves that can be replaced by a 5/2-way solenoid valve of the type shown.. – If measures are required to convert the valve, describe these. Note By „conversion measures“ we understand the simplest of conversions such as the sealing of working ports 2 or 4 using a blanking plug. 4
2
14 1M1 5
1
Symbol
3
Description of valve type
Replacement possible
Description of necessary conversions
2 12 1M1
1 2
12 1M1
1
3 2
10 1M1
1 4
14 1M1
1
3 2
3
© Festo Didactic GmbH & Co. KG • 541090
A-37
Exercise 4: Realising the operation of a hinged lid
Exercise 4: Realising the operation of a hinged lid Name:
Date:
Fundamentals: Selecting solenoid valves
Sheet 2 of 3
Valves are selected according to the following criteria: • Exercise definition, • Required behaviour in the event of power failure, • Minimum possible overall costs The following valves are available for selection for the actuation of a single-acting cylinder: • A pilot actuated, spring return 3/2way solenoid valve with manual override, • A pilot actuated, spring-return 5/2-way solenoid valve with manual override – Select a valve and explain the reasons for your decision. Note Apart from the cost of the valve, the above overall costs also include the cost of installation, maintenance and storage for replacement parts. Valve type
A-38
Reason
© Festo Didactic GmbH & Co. KG • 541090
Exercise 4: Realising the operation of a hinged lid
Exercise 4: Realising the operation of a hinged lid Name:
Date:
Fundamentals: Logic operations: The OR function
Sheet 3 of 3
Triggering the advancing of a cylinder piston rod is to be possible using two pushbuttons S1 and S2. If at least one of the two pushbuttons is actuated, the valve coil 1M1 is energised, the solenoid valve 1V1 switches into the actuated position and the piston rod advances. If both pushbuttons are released, the valve switches into the initial position and the piston rod retracts. – Create the appropriate function table and the logic symbol. Note 0 means: Pushbutton not actuated, i.e. piston rod does not advance 1 means: Pushbutton actuated, i.e. piston rod advances S1
S2
1M1
1V1
Function table
Logic symbol
© Festo Didactic GmbH & Co. KG • 541090
A-39
Exercise 4: Realising the operation of a hinged lid
Exercise 4: Realising the operation of a hinged lid Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 1 of 2
– Design the pneumatic and electrical circuit diagrams for the operation of the hinged lid.
Pneumatic circuit diagram
A-40
© Festo Didactic GmbH & Co. KG • 541090
Exercise 4: Realising the operation of a hinged lid
Exercise 4: Realising the operation of a hinged lid Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 2 of 2
1
+24 V
2
3
12
14
K1 11
A1 K1
1M1 A2
0V 11
12 14
21
22 24
31
32 34
41
42 44
Electrical circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
A-41
Exercise 4: Realising the operation of a hinged lid
Exercise 4: Realising the operation of a hinged lid Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Compile the equipment list by entering the required equipment in the table below. Quantity
Description
Equipment list
A-42
© Festo Didactic GmbH & Co. KG • 541090
Exercise 5: Realising a diverting device
Training aims
• To familiarise yourself with the design and mode of operation of a double-acting cylinder. • To familiarise yourself with the design and mode of operation of a double solenoid valve.
Problem definition
Packages are to be pushed from one conveyor to another via a diverting device.
Parameters
• A double-acting cylinder is to be used. • The cylinder control is to be effected indirectly and via a pushbutton. In the event of power failure the cylinder piston rod is to remain in the current position.
Project task
1. Answer the questions and carry out the exercises regarding the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
© Festo Didactic GmbH & Co. KG • 541090
A-43
Exercise 5: Realising a diverting device
Positional sketch
Diverting device
1. Pressing of a pushbutton is to cause the frame of the diverting device to be advanced. The package is transferred and transported away. 2. Pressing of another pushbutton causes the frame to be moved into the initial position.
A-44
© Festo Didactic GmbH & Co. KG • 541090
Exercise 5: Realising a diverting device
Exercise 5: Realising a diverting device Name:
Date:
Fundamentals: Use of solenoid valves
Sheet 1 of 4
Two factors are to be considered regarding the question as to which valve type is to be used for a particular application: • Duration, i.e. time frame, • Quantity or frequency of required switching operations. In order to utilise a directional control valve as efficiently as possible, you will need to decide in each case whether the use • of a double solenoid valve or • a spring-return directional control valve is more cost effective for the required application. – Decide whether a double solenoid or a spring-return solenoid valve seems more cost effective for the applications listed and explain the reasons for your choice. Application 1 The clamping cylinder of a milling device is to firmly hold in position a workpiece for the duration of a milling operation (duration of approx. 10 min, 60 clamping operations per day). Valve type
Reason
Application 2 The ejecting cylinder of a sorting device is to push defective workpieces from a conveyor (duration of approx.1s, 600 ejecting operations per day). Valve type
© Festo Didactic GmbH & Co. KG • 541090
Reason
A-45
Exercise 5: Realising a diverting device
Exercise 5: Realising a diverting device Name:
Date:
Fundamentals: Mode of operation of a solenoid valve
Sheet 2 of 4
– Describe the mode of operation of the directional control valve shown.
4
2
5
3
1M1
1M2 1
Description of mode of operation of a directional control valve
A-46
© Festo Didactic GmbH & Co. KG • 541090
Exercise 5: Realising a diverting device
Exercise 5: Realising a diverting device Name:
Date:
Fundamentals: Calculating the current consumption of a valve coil
Sheet 3 of 4
A spring-return solenoid valve is to be switched via pushbutton S1. – Calculate the current consumption of the valve coil 1M1 at a voltage supply of 24 V DC and a coil resistance of 48 Ω (Ohm). +24 V
1
13 S1 14
1M1
0V Current consumption in 1M1
© Festo Didactic GmbH & Co. KG • 541090
Power rating of 1M1
A-47
Exercise 5: Realising a diverting device
Exercise 5: Realising a diverting device Name:
Date:
Fundamentals: Calculate the current consumption of a valve coil
Sheet 4 of 4
– Would the current consumption in 1M1 be the same, higher or lower if the above valve coil is connected to a 24V AC voltage? Explain the reasons for your answer. Identical
A-48
Higher
Lower
Reason
© Festo Didactic GmbH & Co. KG • 541090
Exercise 5: Realising a diverting device
Exercise 5: Realising a diverting device Name:
Date:
Completing the pneumatic and electrical circuit diagram
Sheet 1 of 2
– Design the pneumatic and electrical circuit diagrams for the diverting device.
1
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
A-49
Exercise 5: Realising a diverting device
Exercise 5: Realising a diverting device Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 2 of 2
+24 V
1
0V
2
3
11
12 14
11
12 14
21
22 24
21
22 24
31
32 34
31
32 34
41
42 44
41
42 44
4
Electrical circuit diagram
A-50
© Festo Didactic GmbH & Co. KG • 541090
Exercise 5: Realising a diverting device
Exercise 5: Realising a diverting device Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Compile the equipment list by entering the required equipment in the table below. Quantity
Description
Equipment list
© Festo Didactic GmbH & Co. KG • 541090
A-51
Exercise 5: Realising a diverting device
A-52
© Festo Didactic GmbH & Co. KG • 541090
Exercise 6: Actuation of a stacking magazine
Training aims
• To be able to use a double-acting cylinder. • To familiarise yourself with the design and mode of operation of a double solenoid valve. • To familiarise yourself with the option of sensing the end positions of cylinders.
Problem definition
Wooden boards are to be pushed from a stacking magazine into an assembly device.
Parameters
• The forward end position of the cylinder is to be sensed.
Project task
1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
© Festo Didactic GmbH & Co. KG • 541090
A-53
Exercise 6: Actuation of a stacking magazine
Positional sketch
Stacking magazine
1. Pressing of a pushbutton causes a wooden board to be pushed out of the stacking magazine. 2. Once the forward end position is reached, the slide is moved into the initial position.
A-54
© Festo Didactic GmbH & Co. KG • 541090
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine Name:
Date:
Fundamentals: Components of an electropneumatic system
Sheet 1 of 6
The components of an electropneumatic system are represented in a pneumatic circuit diagram and/or in an electrical circuit diagram. – Determine where the components below are to be represented. Component
Pneumatic circuit diagram
Electrical circuit diagram
Manually operated pushbutton Cylinder Valves Valve coils Relay Electromechanical limit switch Electronic proximity sensor Indicating devices
© Festo Didactic GmbH & Co. KG • 541090
A-55
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine Name:
Date:
Fundamentals: Components of an electropneumatic system
Sheet 2 of 6
The function of sensors in electropneumatic control systems is to acquire information and to transmit this for signal processing. – What function(s) can an electromechanical limit switch fulfill in an electropneumatic control system? Description: Function(s) of electromechanical limit switches
A-56
© Festo Didactic GmbH & Co. KG • 541090
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine Name:
Date:
Fundamentals: Representation of limit switches
Sheet 3 of 6
Limit switches can be actuated in different ways, via the function of a normally closed or normally open contact or changeover switch and, in the normal position of the system, can be either actuated or unactuated. – Describe the appropriate design or function of the symbols shown. Description: Design/function
Symbol
2 1 4 1
© Festo Didactic GmbH & Co. KG • 541090
A-57
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine Name:
Date:
Fundamentals: Creating a logic element table
Sheet 4 of 6
One possibility of recording the allocated contacts of a relay is by means of listing these in a logic element table. – Create the logic element tables for relays K6 and K9. 10
+24 V
14
...
12
11 12
K5
14
K6 11
12 12
14
K2 11
13 12
14
K7 11
14 12
14
K4 11
15 12
14
K8 11
16 14
12 K3
11
17 12
14
K9 11
18
19
34
32
34
32
K6
K7
11
31
31
14
12 K1
11
22
24
K9
22
24
K6 21
K8
34
K9
32
34
K8 31
31
A1 K9
A2
32
21
A1 K8
A2
24
22
21
A1 K7
A2
24
K7 21
A1 K6
22
1M1
2M1
A2
0V
...
Electrical circuit diagram
Logic element
Description: Logic element table
table K6
K9
A-58
© Festo Didactic GmbH & Co. KG • 541090
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine Name:
Date:
Fundamentals: Creating a logic element table
Sheet 5 of 6
Another method of recording the allocated contact sets of a relay can be seen in the electrical circuit diagram below. +24 V
1
2
4
3
6
5
8
7
11
10
9
21
12
25
14
K11
NA EMERGENCY 22 STOP
1B2
2B1
13
2B2 S1 Start
32
K11 11
1B1
27 24
22
12
13
14 12
12 K5
14 12
14 12
K6 11
14
16 14 12
K7 11
11
17
14 12
K4 11
14 12
K8 11
18 14 12
K3 11
20
19 14 22
K9 11
21
24 12
K1 11
14 32
K10 21
22 34
23 34
32
K6
34
32
K7
11
21
24
31
31
26 34 22
32
K8
K9
31
34
K11
24
K3
31
31
21
14
12 K1
11
24
22 K10
A1 K11
A1 K1
K2
A2 0V
A1
A1 K3
A2
A1 K4
A2
A1 K5
A2
K6
K7
24
22 K8
24
22
21
21
A1
A1
A1
A1
A1
K8
A2
K9
A2
44
42 K7
K9
21
K7
A2
24
22
21
K6
A2
24
22
21
44
42 K8
1M1
44
42 K9
41 2M1
34
32 K10
41
41 2M2
31 1M2
K10
A2
A2
A2
11
12 14 .11
11
12 14 .12
11
12 14 .14
11
12 14 .18
11
12 14 .16 11
12 14 .12
11
12 14 .13
11
12 14 .15
11
12 14 .17
11
12 14 .19
11
12 14 .21
21
22 24 .25
21
22 24 .20
21
22 24
21
22 24 .27
21
22 24
21
22 24
21
22 24 .14
21
22 24 .16
21
22 24 .18
21
22 24 .20
21
22 24 .12
31
32 34 .27
31
32 34
31
32 34
31
32 34
31
32 34
31
32 34
31
32 34 .22
31
32 34 .23
31
32 34 .24
31
32 34 .26
31
32 34 .26
41
42 44
41
42 44
41
42 44
41
42 44
41
42 44
41
42 44
41
42 44
41
42 44 .22
41
42 44 .23
41
42 44 .24
41
42 44
1A1+
2A1+
2A1-
1A1-
Electrical circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
A-59
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine Name:
Date:
Fundamentals: Creating a logic element table
Sheet 6 of 6
– Complete the information regarding the relays shown by: Indicating the current path in which the respective contact is used and specifying the function fulfilled by the contact set (normally open or normally closed contact). Relay
Current path
Function:
Function:
Normally open contact
Normally closed contact
Relay K9
Relay K10
A-60
© Festo Didactic GmbH & Co. KG • 541090
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 1 of 2
– Design the pneumatic and electrical circuit diagrams for the stacking magazine. 1A1
1V2
1V1
1
1
2
2
4
5
1V3
2
1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
A-61
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 2 of 2
+24 V
1
3
2
12
4
14
K1
A1
14
K2 11
K1
12
11
A1 K2
A2 0V
A2
11
12 14
11
12 14
21
22 24
21
22 24
31
32 34
31
32 34
41
42 44
41
42 44
Electrical circuit diagram
A-62
© Festo Didactic GmbH & Co. KG • 541090
Exercise 6: Actuation of a stacking magazine
Exercise 6: Actuation of a stacking magazine Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Compile the equipment list by entering the required equipment in the table below. Quantity
Description
Equipment list
© Festo Didactic GmbH & Co. KG • 541090
A-63
Exercise 6: Actuation of a stacking magazine
A-64
© Festo Didactic GmbH & Co. KG • 541090
Exercise 7: Sorting of packages
Training aims
• • • •
Problem definition
Packages are to be transported on a conveyor past workstations. The packages can be diverted by means of deflectors.
Parameters
• A double-acting cylinder is to be used. • The cylinder control is to be effected indirectly via pushbuttons and electromechanical limit switches. • Triggering of the advancing movement is to be possible only if the piston rod is in the retracted end position.
Project task
1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
To be able to calculate piston forces according to specific values To be able to calculate electrical characteristic values To be able to explain and design an example of indirect actuation To familiarise yourself with logic functions and to be able to design these
© Festo Didactic GmbH & Co. KG • 541090
A-65
Exercise 7: Sorting of packages
Positional sketch
Conveyor belt for packages
1. The piston rod of a cylinder is to advance automatically as soon as pushbutton S1 is actuated. 2. If the pushbutton is no longer actuated, the piston rod is to assume the retracted end position.
A-66
© Festo Didactic GmbH & Co. KG • 541090
Exercise 7: Sorting of packages
Exercise 7: Sorting of packages Name:
Date:
Fundamentals: Calculation of piston force
Sheet 1 of 3
The piston of a double-acting cylinder has a diameter of 16 mm and the piston rod a diameter of 8 mm. The frictional losses within the cylinder are 10 %. The following applies for double-acting cylinders: Advance stroke Return stroke
Feff Feff Feff A
= = = = =
A'
= =
p FF D d
= = = =
(A • p) – FF (A' • p) – FF Effective piston force (N) Effective piston surface (m2) D2 • π ) ( 4 Effective annular surface (m2) π (D 2 − d 2 ) 4 Working pressure (Pa) Friction force (approx. 10% of Fth ) (N) Cylinder diameter (m) Piston rod diameter (m)
– Calculate the effective piston force in the advance and return stroke at an operating pressure of 6 bar (600 kPa). To be calculated
Solution approach
Advance stroke
Return stroke
© Festo Didactic GmbH & Co. KG • 541090
A-67
Exercise 7: Sorting of packages
Exercise 7: Sorting of packages Name:
Date:
Fundamentals: Calculation of electrical characteristic values
Sheet 2 of 3
A relay in an electropneumatic circuit is designated as follows: 580 Ω, 1 W. – Calculate the permissible operating voltage which ensures that no overload occurs on the relay. To be calculated
Solution approach
Max. Operating voltage
A-68
© Festo Didactic GmbH & Co. KG • 541090
Exercise 7: Sorting of packages
Exercise 7: Sorting of packages Name:
Date:
Fundamentals:
Sheet 3 of 3
Triggering of the advancing movement of the piston rod of a cylinder is to be achieved by means of two pushbuttons S1 and S2. The valve coil 1M1 is energised if both pushbuttons are actuated simultaneously and the solenoid valve 1V1 switches into the actuated position causing the piston rod to advance. If at least one of the two pushbuttons is released, the valve switches into the initial position and the piston rod retracts. – Create an appropriate function table and the logic symbol. Note 0 means: Pushbutton not actuated, i.e. piston rod not advancing 1 means: Pushbutton actuated, i.e. piston rod advances S1
S2
1M1
1V1
Function table
Logic symbol
© Festo Didactic GmbH & Co. KG • 541090
A-69
Exercise 7: Sorting of packages
Exercise 7: Sorting of packages Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 1 vof 2
– Configure the pneumatic circuit diagram and design the electrical circuit diagram for the feeding device. 1A1
1V2
1V1
1B1
1
1
2
2
4
2
5
3
1M1
1B2
1V3
1M2 1
Pneumatic circuit diagram
A-70
© Festo Didactic GmbH & Co. KG • 541090
Exercise 7: Sorting of packages
Exercise 7: Sorting of packages Name:
Date:
Completing the pneumatic and electrical circuit diagram
Sheet 2 of 2
+24 V
1
2
A1 K1
3
A1 K2
K3
A2 0V
5
4
1M1
1M2
A2
11
12 14
11
12 14
11
12 14
21
22 24
21
22 24
21
22 24
31
32 34
31
32 34
31
32 34
41
42 44
41
42 44
41
42 44
Electrical circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
A-71
Exercise 7: Sorting of packages
Exercise 7: Sorting of packages Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Compile the equipment list by entering the required equipment in the table below. Quantity
Description
Equipment list
A-72
© Festo Didactic GmbH & Co. KG • 541090
Exercise 8: Actuation of a sliding platform
Training aims
• To familiarise yourself with logic functions and to be able to design these • To be able to explain and design electrical latching circuits with dominant switchoff signal
Problem definition
Wooden boards are to be manually placed onto a sliding platform. The boards are to be pushed under a belt sanding machine by means of a pneumatic drive.
Parameters
• A double-acting cylinder is to be used. • The cylinder control is to be effected indirectly.
Project task
1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile the equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
© Festo Didactic GmbH & Co. KG • 541090
A-73
Exercise 8: Actuation of a sliding platform
Positional sketch
Sliding platform
1. The piston rod of a cylinder is to advance if pushbutton S1 is actuated. 2. Actuation of pushbutton S2 is to cause the piston rod to retract.
A-74
© Festo Didactic GmbH & Co. KG • 541090
Exercise 8: Actuation of a sliding platform
Exercise 8: Actuation of a sliding platform Name:
Date:
Fundamentals: Signal storage
Sheet 1 of 3
The actuation of the pushbutton must be stored if the piston rod of a cylinder is to also advance if the pushbutton is only briefly actuated. This signal storage can be effected either in the power section or in the signal control section of a circuit. – Describe how signal storage is devised in the power section or in the signal control section respectively. Place of signal storage
Description: Signal storage
Signal storage in the power section
Signal storage in the signal control section
© Festo Didactic GmbH & Co. KG • 541090
A-75
Exercise 8: Actuation of a sliding platform
Exercise 8: Actuation of a sliding platform Name:
Date:
Fundamentals: Analysing circuits
Sheet 2 of 3
– Describe the behaviour of the circuit specified (pilot actuated, spring-return 5/2-way solenoid valve with manual override, double-acting cylinder) in the event of – Power failure – Pressure failure.
Power failure
A-76
Pressure failure
© Festo Didactic GmbH & Co. KG • 541090
Exercise 8: Actuation of a sliding platform
Exercise 8: Actuation of a sliding platform Name:
Date:
Fundamentals: Logic functions
Sheet 3 of 3
The lamp P1 is to be illuminated whenever pushbutton S1 is not actuated. – Draw up the appropriate function table and the logic symbol(s). 0 means: Pushbutton S1 not actuated, i.e. lamp P1 off 1 means: Pushbutton S1 actuated, i.e. P1 illuminated S1
P1
Function table
Logic symbol
© Festo Didactic GmbH & Co. KG • 541090
A-77
Exercise 8: Actuation of a sliding platform
Exercise 8: Actuation of a sliding platform Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 1 of 2
– Design the pneumatic and electrical circuit diagrams for the sliding platform.
4
5
2
1
3
Pneumatic circuit diagram
A-78
© Festo Didactic GmbH & Co. KG • 541090
Exercise 8: Actuation of a sliding platform
Exercise 8: Actuation of a sliding platform Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 2 of 2
+24 V
1
2
3
A1 K1
1M1 A2
0V 11
12 14
21
22 24
31
32 34
41
42 44
Electrical circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
A-79
Exercise 8: Actuation of a sliding platform
Exercise 8: Actuation of a diverting device Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Compile the equipment list by entering the required equipment in the table below. Quantity
Description
Equipment list
A-80
© Festo Didactic GmbH & Co. KG • 541090
Exercise 9: Expanding a diverting device
Training aims
• To familiarise yourself with different types of end position control and to be able to select a suitable type. • To familiarise yourself with latching circuits of different characteristics.
Problem definition
Packages are to be transferred from one conveyor belt to another via a diverting device using reciprocating strokes. Once switched on, the device is to run continuously and only be switched off via a stop signal.
Parameters
• The latching circuit used is to exhibit a dominant „Off“ behaviour.
Project task
1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagram. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile the equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
© Festo Didactic GmbH & Co. KG • 541090
A-81
Exercise 9: Expanding a diverting device
Positional sketch
Diverting device for packages
1. Actuation of the pushbutton is to cause a reciprocating movement of the cylinder piston rod to drive the diverting device via a latching drive. 2. The packages are to be deflected and transported in the opposite direction. 3. Pressing of a second pushbutton is to switch off the drive.
A-82
© Festo Didactic GmbH & Co. KG • 541090
Exercise 9: Expanding a diverting device
Exercise 9: Expanding a diverting device Name:
Date:
Fundamentals: Latching circuits
Sheet 1 of 4
A latching relay circuit is required in order to store a signal in the signal control section. – The relay K1 is energised by actuating pushbutton S1. Complete the electrical circuit diagram below so that the relay latches after the pushbutton S1 is released. +24 V
1
13 S1 14
A1 K1 A2 0V 11
12 14
21
22 24
31
32 34
41
42 44
Electrical circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
A-83
Exercise 9: Expanding a diverting device
Exercise 9: Expanding a diverting device Name:
Date:
Fundamentals: Latching circuits
Sheet 2 of 4
An additional normally closed contact is required in order to cancel a set selflatching loop. Differentiation is made between two groups depending on the configuration of this normally closed contact: • Dominant setting self-latching loop • Dominant resetting self-latching loop – Complete the electrical circuit diagram below so that the self-latching loop is reliably cancelled via the actuation of a pushbutton S2. +24 V
1
13 S1 14
A1 K1 A2 0V 11
12 14
21
22 24
31
32 34
41
42 44
Electrical circuit diagram
A-84
© Festo Didactic GmbH & Co. KG • 541090
Exercise 9: Expanding a diverting device
Exercise 9: Expanding a diverting device Name:
Date:
Fundamentals: Latching circuits
Sheet 3 of 4
The various circuits for signal storage exhibit different behaviour: • with simultaneously applicable set and reset conditions • in the event of power failure or cable fracture – Complete the table and enter the behaviour of the respective valve. Valve position unchanged/valve is actuated/valve switches to normal position Signal storage via double solenoid valve
Signal storage via electrical latching circuit combined with spring-return valve Dominant setting
Dominant resetting
Set and reset signal shared Power failure
© Festo Didactic GmbH & Co. KG • 541090
A-85
Exercise 9: Expanding a diverting device
Exercise 9: Expanding a diverting device Name:
Date:
Fundamentals: Limit switches and proximity sensors
Sheet 4 of 4
The function of limit switches and proximity sensors is to acquire information and to transmit this for signal processing. These include: Mechanical position switches (limit switches), magnetic proximity sensors (reed switches), optical proximity sensors, capacitive proximity sensors, inductive proximity sensors – Allocate the designations to the corresponding symbols in the table. Designation
Symbol BN BK BU BN BK BU BN BK BU
4
2
1
BN BK BU
A-86
© Festo Didactic GmbH & Co. KG • 541090
Exercise 9: Expanding a diverting device
Exercise 9: Expanding a diverting device Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 1 of 2
– Design the pneumatic and electrical circuit diagram for the diverting device. 1A1
1V2
1V1
1
1
2
2
4
2
5
3
1M1
1V3
1M2 1
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
A-87
Exercise 9: Expanding a diverting device
Exercise 9: Expanding a diverting device Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 1 of 2
+24 V
1
2
13 S1
12
3
4
5
7
6
8
14
K1 14
11
31 S2 32
A1 K1
1M1
1M2
A2 0V 11
12 14
21
22 24
31
32 34
41
42 44
Electrical circuit diagram
A-88
© Festo Didactic GmbH & Co. KG • 541090
Exercise 9: Expanding a diverting device
Exercise 9: Expanding a diverting device Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Compile the equipment list by entering the required equipment in the table below. Quantity
Description
Equipment list
© Festo Didactic GmbH & Co. KG • 541090
A-89
Exercise 9: Expanding a diverting device
A-90
© Festo Didactic GmbH & Co. KG • 541090
Exercise 10: Designing a stamping device
Training aims
• To be able to design a pressure-dependent reversal control. • To familiarise yourself with the design and mode of operation of magnetic proximity sensors.
Problem definition
Small mounting blocks are to be stamped during the production of door frames. These blocks are to be stamped by means of a stamping device.
Parameters
• The stamping pressure is to be 5.5 bar (550 kPa).
Project task
1. Answer the questions or carry out the exercises regarding the fundamentals of the training contents listed. 2. Design the pneumatic and electrical circuit diagrams. 3. Simulate the electropneumatic circuit diagram and check its correct functioning. 4. Compile an equipment list. 5. Carry out the pneumatic and electrical circuit assembly. 6. Check the circuit operation.
© Festo Didactic GmbH & Co. KG • 541090
A-91
Exercise 10: Designing a stamping device
Positional sketch
Stamping device
1. The pressing of a pushbutton is to cause the stamping device to advance and the workpiece to be stamped. 2. The stamping tool is to return into the initial position once the stamping pressure is obtained.
A-92
© Festo Didactic GmbH & Co. KG • 541090
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device Name:
Date:
Fundamentals: Magnetic proximity sensor
Sheet 1 of 5
In contrast with limit switches proximity sensors are switched contactlessly and without an external mechanical actuating force. – Describe the design and function of a magnetic proximity sensor (reed switch). Description: Design and function
Symbol
Schematic representation
BN BK BU
© Festo Didactic GmbH & Co. KG • 541090
A-93
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device Name:
Date:
Fundamentals: Magnetic proximity sensors
Sheet 2 of 5
As regards polarity there are two different designs of electronic proximity sensors, i.e. PNP or NPN. – Describe the differences between these two types. PNP
A-94
NPN
© Festo Didactic GmbH & Co. KG • 541090
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device Name:
Date:
Fundamentals: Pressure switches
Sheet 3 of 5
Pressure sensitive sensors, so-called PE converters, are used to monitor the pressure in a system. – Describe the mode of operation of PE converter. Description of mode of operation
© Festo Didactic GmbH & Co. KG • 541090
A-95
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device Name:
Date:
Fundamentals: Pressure sensors
Sheet 4 of 5
Pressure sensors can be divided into two groups whereby differentiation is made between: • Pressure sensors with mechanical contact (mechanical principle of action) • Pressure sensors with electronic switching (electronic principle of action) – Describe the purpose and function of the pressure sensor shown below. Description: Purpose and function
A-96
Symbol
Schematic representation
© Festo Didactic GmbH & Co. KG • 541090
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device Name:
Date:
Fundamentals: Choice of proximity sensors
Sheet 5 of 5
The end positions of a drive cylinder are to be sensed by means of proximity sensors. The following requirements apply regarding the proximity sensors: • The end positions of the piston rod are to be sensed contactlessly • The proximity sensors are to be insensitive to dust • The piston rod and trip cam of the cylinder are made of metal – Choose which proximity sensors meet the specified requirements and explain your reasons for this. Proximity sensor
© Festo Didactic GmbH & Co. KG • 541090
Reason
A-97
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 1 of 2
– Design the pneumatic and electrical circuit diagrams for the stamping device. 1A1
1V2
1V1
1
1
2
2
4
2
5
3
1M1
1V3
1M2 1
Pneumatic circuit diagram
A-98
© Festo Didactic GmbH & Co. KG • 541090
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 1 of 2
+24 V
1
3
2
1B1
5
4
1B2
7
6
8
1B3 p
A1 K1
A1 K2
A2 0V
A1 K3
1M1
A2
1M2
A2
11
12 14
11
12 14
11
12 14
21
22 24
21
22 24
21
22 24
31
32 34
31
32 34
31
32 34
41
42 44
41
42 44
41
42 44
Electrical circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
A-99
Exercise 10: Designing a stamping device
Exercise 10: Designing a stamping device Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Compile the equipment list by entering the required equipment in the table below. Quantity
Description
Equipment list
A-100
© Festo Didactic GmbH & Co. KG • 541090
Exercise 11: Realising a pallet loading station
Training aims
• To familiarise yourself with displacement-step diagrams and to be able to design these for specified problem definitions. • To be able to realise a sequence control using two cylinders.
Problem definition
Stacks of roof tiles are to be strapped with a band and then transported to a pallet loading station, where they are to be transferred onto Euro pallets.
Parameters
• Adjust the one-way flow control valve so that both cylinders retract at identical speed.
Project task
1. 2. 3. 4. 5. 6. 7.
Design the displacement-step diagram. Draw up the corresponding function diagram and function chart. Design the pneumatic and electrical circuit diagrams. Simulate the electropneumatic circuit diagram and check its correct functioning. Compile an equipment list. Carry out the pneumatic and electrical circuit assembly. Check the circuit operation.
© Festo Didactic GmbH & Co. KG • 541090
A-101
Exercise 11: Realising a pallet loading station
Positional sketch
Pallet loading station
1. Cylinder 1A1 is to advance when pushbutton S1 is pressed, whereby a single package arrives at the loading point and sensor 1B2 is actuated. 2. Cylinder 2A1 advances, actuates sensor 2B2, and pushes the package onto the pallet. 3. If 2B2 is actuated and S1 is unactuated, cylinder 1A1 retracts. 1B2 is therefore no longer actuated and cylinder 2A1 retracts. Consequently, the overall sequence is: 1A1+ 2A1+ 1A1– 2A1–
A-102
© Festo Didactic GmbH & Co. KG • 541090
Exercise 11: Realising a pallet loading station
Exercise 11: Realising a pallet loading station Name:
Date:
Fundamentals: Designing the displacement-step diagram
Sheet 1 of 3
If pushbutton S1 is actuated, cylinder 1A1 advances whereby the package reaches its loading point and sensor 1B2 is actuated. Cylinder 2A1 advances, actuates sensor 2B2 and pushes the package onto the pallet. If 2B2 is actuated and S1 unactuated, cylinder 1A1 retracts. 1B2 is no longer actuated and cylinder 2A1 retracts. Consequently the overall sequence is: 1A1+ 2A1+ 1A1– 2A1– – Design the displacement-step diagram for the problem definition described.
1
2
3
4=1
1
1A1 0
1
2A1 0
Displacement-step diagram
© Festo Didactic GmbH & Co. KG • 541090
A-103
Exercise 11: Realising a pallet loading station
Exercise 11: Realising a pallet loading station Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 1 of 2
– Design the pneumatic and electrical circuit diagrams for the pallet loading station. 1A1
1V2
1V1
1
1
2
2
4
5
2A1
2
1
3
1V3
2V2
2
1 2V1
2
1
3
Pneumatic circuit diagram
A-104
© Festo Didactic GmbH & Co. KG • 541090
Exercise 11: Realising a pallet loading station
Exercise 11: Realising a pallet loading station Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 2 of 2
+24 V
1
3
2
1B2 BN
5
4
6
7
8
2B2 BN BK
BK
BU
BU
A1
A1
A1
A2
A2
A2
1M1
0V 11
12 14
11
12 14
11
12 14
21
22 24
21
22 24
21
22 24
31
32 34
31
32 34
31
32 34
41
42 44
41
42 44
41
42 44
1M2
2M1
Electrical circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
A-105
Exercise 11: Realising a pallet loading station
Exercise 11: Realising a pallet loading station Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Compile the equipment list by entering the required equipment in the table below. Quantity
Description
Equipment list
A-106
© Festo Didactic GmbH & Co. KG • 541090
Exercise 12: Eliminating a fault on the pallet loading station
Training aims
• To be able to identify and eliminate faults in simple electropneumatic control systems.
Problem definition
The pallet loading station stops during continuous operation. A fault has occurred and must be eliminated. Thereafter the pallet loading station is to be re-started.
Parameters
• Only one fault has occurred.
Project task
1. Describe the behaviour of the control system. Compare this with the correct control system behaviour. Use the displacement-step diagram to assist you. 2. Localise potential causes of the fault with the help of the pneumatic and electrical circuit diagrams. 3. Find the fault in the control system and eliminate it. 4. Re-start the control system.
© Festo Didactic GmbH & Co. KG • 541090
A-107
Exercise 12: Eliminating a fault on the pallet loading station
Positional sketch
Pallet loading station
1. Cylinder 1A1 is to advance if pushbutton S1 is pressed. This causes a single package to reach its loading point thereby actuating sensor 1B2. 2. Cylinder 2A1 advances, actuates sensor 2B2 and pushes the package onto the pallet. 3. If 2B2 is actuated and S1 unactuated, cylinder 1A1 retracts, 1B2 is no longer actuated and cylinder 2A1 retracts. Consequently the overall sequence is: 1A1+ 2A1+ 1A1– 2A1–
A-108
© Festo Didactic GmbH & Co. KG • 541090
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station Name:
Date:
Fault finding in simple electropneumatic circuits
Sheet 1 of 4
The following fault occurs in the circuit shown below: The piston rod of cylinder 1A1 and the piston rod of cylinder 2A1 advance and remain in the forward end position. – Describe what the potential causes of the fault could be. 1A1
1V2
1V1
2A1
1B2
1
1
2
2
4
2
5
3
1M1
1V3
2
1 2V1 1M2
1
2V2
2B2
2M1
2
1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
A-109
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station Name:
Date:
Fault finding in simple electropneumatic circuits
Sheet 2 of 4
+24 V
1B2
1
3
2
BN
2B2
5
4
BN
13
BK
BK
S1 14
A1 K1
A1 K2
14
7
12
14
K2 11
8
12
14
K1 11
11
A1 K3
A2 0V
12 K3
BU
BU
6
1M1
A2
1M2
2M1
A2
11
12 14 .8
11
12 14 .7
11
12 14 .6
21
22 24
21
22 24
21
22 24
31
32 34
31
32 34
31
32 34
41
42 44
41
42 44
41
42 44
Electrical circuit diagram
List of potential causes of faults
A-110
© Festo Didactic GmbH & Co. KG • 541090
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station Name:
Date:
Fault finding in simple electropneumatic circuits
Sheet 3 of 4
A cable break occurs at the areas marked in the circuit shown below. – Describe what the effects of a cable break at these respective points are on the functioning of the circuit. +24 V
1B2
1
3
2
5
4
2B2 BN
BN BK
6
13
BK
S1
12
14 BU
14
K3
7
12
14
K2 11
8
12
14
K1 11
11
BU
A1 K1
A1 K2
A2 0V
A1 K3
1M1
A2
1M2
2M1
A2
11
12 14 .8
11
12 14 .7
11
12 14 .6
21
22 24
21
22 24
21
22 24
31
32 34
31
32 34
31
32 34
41
42 44
41
42 44
41
42 44
Electrical circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
A-111
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station Name:
Date:
Fault finding in simple electropneumatic circuits
Sheet 4 of 4
Fault
Effect of fault
Break in earthing wire of relay K1 (current path 2)
Break in signal line of sensor 2B2 (current path 4)
Break in supply line of relay K3 (current path 5)
Break in supply line of relay contact 14 at K2 (current path 7) Break in earthing wire 2M1 (current path 8)
A-112
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Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station Name:
Date:
Fault finding: Determining the required status
Sheet 1 of 9
– Create the displacement-step diagram with the help of the documentation given out. Components
Time Step 1
Designation
Identification
2
3
4
5
6
7
8
9
10
Signal
Displacement-step diagram
© Festo Didactic GmbH & Co. KG • 541090
A-113
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault in the pallet loading station Name:
Date:
Fault finding: Setpoint/actual comparison
Sheet 2 of 9
Determine the ACTUAL status of the system with the help of the following documentation: • Positional sketch with problem description • Graphic representation – If the correct function is not given (REFERENCE/ACTUAL comparison), clearly mark the area in the diagram where the fault occurs. Components
Time Step 1
Designation
Identification
2
3
4
5
6
7
8
9
10
Signal
Displacement-step diagram
A-114
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Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station Name:
Date:
Fault finding: Description of faults
Sheet 3 of 9
You have marked the area where a fault occurs in the diagram of the worksheet ‘REFERENCE/ACTUAL comparison. – Describe the process up the point where the station or system stops. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
© Festo Didactic GmbH & Co. KG • 541090
A-115
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station Name:
Date:
Fault finding: Definition of faults - pneumatics
Sheet 4 of 9
Once you have established the ACTUAL status of the system, consider what the causes of the faults could be. In which pneumatic tubing connections could the fault occur? – Enter all the possibilities and indicate components at the start and end of the tubing connection in order to ensure clear identification. Potential fault No.
Tubing connection Start
End
Potential faults
A-116
© Festo Didactic GmbH & Co. KG • 541090
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station Name:
Date:
Fault finding: Definition of faults – electrics
Sheet 5 of 9
Once you have established the ACTUAL status of the system, consider what the causes of the faults could be. • In which current paths could the fault be located? • What is the function of the current path? – Enter all the possibilities. Potential fault No.
Current path No.
Function of current path
Potential faults
© Festo Didactic GmbH & Co. KG • 541090
A-117
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station Name:
Date:
Fault finding: Localisation of faults - pneumatics
Sheet 6 of 9
Investigate the potential causes of errors you have found in the pneumatics. • Use the same fault numbering that you have used for the worksheet ‘Definition of faults – pneumatic. • Document the procedure used to investigate the tubing connections. – Enter the results of your investigation. Measuring and test protocol Potential fault No.
Tubing connection Start
Inspection
Result
End
Measuring and test protocol
A-118
© Festo Didactic GmbH & Co. KG • 541090
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station Name:
Date:
Fault finding: Localisation of faults
Sheet 7 of 9
Investigate the potential error causes you have found. • Use the same fault numbering that you have used in the worksheet ‘Definition of faults - electrics’. • Document the procedure you have used to check the line connection. – Enter the result of the investigation. Measuring and test protocol Potential fault No.
Current path No.
Measuring points
Inspection
Result
Measuring and test protocol
© Festo Didactic GmbH & Co. KG • 541090
A-119
Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station Name:
Date:
Fault finding: Elimination of fault
Sheet 8 of 9
Once you have localised the failure location, your procedure for the elimination of the fault must be documented on this worksheet. – Describe each of the steps carried out in detail. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
Note In the event of the system not fulfilling the intended function return to the first worksheet and repeat the fault finding. Ask for new worksheet s to do so.
A-120
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Exercise 12: Eliminating a fault on the pallet loading station
Exercise 12: Eliminating a fault on the pallet loading station Name:
Date:
Fault finding: Re-starting
Sheet 9 of 9
Once you have identified, localised and eliminated the fault, re-start the system in accordance with the required status. Reset the specified required times. – Briefly document the procedure followed in note form. _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________ _____________________________________________________________________
© Festo Didactic GmbH & Co. KG • 541090
A-121
Exercise 12: Eliminating a fault on the pallet loading station
A-122
© Festo Didactic GmbH & Co. KG • 541090
Part B – Fundamentals
The theoretical fundamentals for the electropneumatics training package are summarised in the textbook: Electropneumatics, Basic Level This textbook represents an impressive synthesis of years of experience gained in Festo Didactic courses and the requirements of company and college training. It explains basic equipment and modern installation-saving components that require little maintenance. A comprehensive description of methods of representation showing motion sequences and operating states makes complex circuits easy to understand. A detailed example provides students with the necessary knowledge for the planning and implementation of an electropneumatic circuit. G. Prede, D. Scholz, 2001 edition, 296 pages, bound Order No.: 091181
© Festo Didactic GmbH & Co. KG • 541090
B-1
B-2
© Festo Didactic GmbH & Co. KG • 541090
Contents
Part C – Solutions
Exercise 1: Realising a sorting device ____________________________________C-3 Exercise 2: Realising a shut-off device___________________________________C-15 Exercise 3: Realising a lid press ________________________________________C-23 Exercise 4: Realising the operation of a hinged lid _________________________C-33 Exercise 5: Realising a diverting device __________________________________C-41 Exercise 6: Actuation of a stacking magazine _____________________________C-49 Exercise 7: Sorting of packages ________________________________________C-59 Exercise 8: Actuation of a sliding platform _______________________________C-67 Exercise 9: Expanding a diverting device ________________________________C-75 Exercise 10: Designing a stamping device________________________________C-85 Exercise 11: Realising a pallet loading station ____________________________C-95 Exercise 12: Eliminating a fault on the pallet loading station________________C-101
© Festo Didactic GmbH & Co. KG • 541090
C-1
Contents
C-2
© Festo Didactic GmbH & Co. KG • 541090
Exercise 1: Realising a sorting device Solutions
Exercise 1: Realising a sorting device Name:
Date:
Fundamentals: Function of pneumatic working components
Sheet 1 of 7
Pneumatic working components can be divided into two groups: • Working components using linear movement • Working components using rotary movement – Describe the function of the working components shown. Symbol 1
Symbol 2
Symbol 3
Description: Function Symbol 1 Single-acting cylinder, return spring in piston chamber, return stroke via compressed air, forward stroke via return spring. Function The piston rod of this single-acting cylinder is moved into the retracted end position by means of switching on the compressed air. Once the compressed air is switched off the piston reverses into the forward end position via a return spring in the piston chamber (2 operating positions). Symbol 2 Single-acting cylinder, return spring in piston chamber, forward stroke via compressed air, return stroke via return spring Function The piston rod of the single-acting cylinder is moved into the forward end position by means of switching on the compressed air. Once the compressed air is switched off the piston reverses into the retracted end position (2 operating positions). Symbol 3 Pneumatic semi-rotary drive (swivelling drive), with limited swivel range Function This semi-rotary drive is double-acting and is reversed by means of alternating connection of compressed air (2 operating positions).
© Festo Didactic GmbH & Co. KG • 541090
C-3
Exercise 1: Realising a sorting device Solutions
Exercise 1: Realising a sorting device Name:
Date:
Fundamentals: Completing solenoid valve symbols
Sheet 2 of 7
– Complete the individual symbols with the help of the corresponding component descriptions. Description
Symbol
2
Pilot actuated 3/2-way solenoid valve, normally open, with manual override, with spring return
10 1M1
1 2
Pilot actuated 3/2-way solenoid valve, normally closed, with manual override, with spring return
C-4
3
12 1M1
1
3
© Festo Didactic GmbH & Co. KG • 541090
Exercise 1: Realising a sorting device Solutions
Exercise 1: Realising a sorting device Name:
Date:
Fundamentals: Normal positions of directional control valves
Sheet 3 of 7
An electrically actuated 3/2-way solenoid valve has two switching positions. It can be in the normal position (unactuated), or in the switching position (actuated). In the normal position the valve can be closed or open. – Describe the effects on the motion sequence of the following application arising as a result of the different normal positions: The single-acting cylinder shown is controlled by one of the represented 3/2-way solenoid valves respectively. 2 12 1M1
1
2
3
10 1M1
1
3
Description: 3/2-way solenoid valve, normally closed
Description: 3/2-way solenoid valve, normally open
The solenoid valve used is reversed via the
The solenoid valve used is reversed by applying
application of voltage at the solenoid coil; flow is
voltage at the solenoid coil; port 1 (and
released from pressure port 1 to working port 2.
consequently flow) is closed. If the signal is
When the signal is cancelled, the valve is
cancelled the valve is returned to the initial
returned to the initial position via a return spring;
position via a return spring and flow is released
pressure port 1 (and consequently flow) is
from pressure port 1 to working port 2. If the
closed. If the solenoid coil of the directional
solenoid coil of the directional control valve is
control valve is de-energised, the cylinder
de-energised, the cylinder chamber is
chamber is exhausted via the directional control
pressurised via the directional control valve and
valve (exhaust port 3), and the piston rod is
the piston rod is advanced. If the solenoid coil is
retracted. If the solenoid coil is energised, the
energised the directional control valve switches
directional control valve switches. The cylinder
and the cylinder chamber is exhausted via the
chamber is pressurised and the piston is
directional control valve (exhaust port 3),
advanced. If the solenoid coil is de-energised,
causing the piston rod to retract. The valve
the valve reverses. The cylinder chamber is
reverses if the solenoid coil is de-energised. The
exhausted and the piston rod retracts. Consequently the motion sequence is: 1A1+ 1A1-
cylinder chamber is pressurised and the piston
© Festo Didactic GmbH & Co. KG • 541090
rod advances. Consequently the motion sequence is: 1A1- 1A1+
C-5
Exercise 1: Realising a sorting device Solutions
Exercise 1: Realising a sorting device Name:
Date:
Fundamentals: Direct and indirect actuation
Sheet 4 of 7
An electrically actuated solenoid valve can be actuated either directly or indirectly. – Describe the difference with the help of the following application: Electrical actuation of a spring returned 3/2-way solenoid valve using a pushbutton. Description: Direct actuation
Description: Indirect actuation
Current flows through the solenoid coil of the
In the case of indirect control, current flows
valve if the pushbutton is actuated. The solenoid
through a relay coil if a pushbutton is actuated.
is energised and the valve switches into the
The relay contact closes and the valve switches.
actuated position.
The switching position is retained for as long as
The current flow is interrupted if the pushbutton
current flows through the solenoid or relay coil
is released. The solenoid is de-energised and the
(in the case of self-latching loops also after the
directional control valve returns to the initial position.
pushbutton is released). The relay is deenergised if the current flow is interrupted via the relay coil and the valve switches into the initial position. More complex, indirect actuation is always used if the control circuit and primary circuit operate using different voltages, the current through the coil of the directional control valve exceeds the permissible current for the pushbutton, if several valves are switched using one pushbutton or extensive logic functions are required between the signals of various pushbuttons.
C-6
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Exercise 1: Realising a sorting device Solutions
Exercise 1: Realising a sorting device Name:
Date:
Design and function of an electrical switch
Sheet 5 of 7
Switches are basically divided into pushbutton and control switch designs and perform the function of a normally closed contact, normally open contact or changeover switch. – Describe the design and function of the switches shown. Symbol 1
Symbol 2
3 4
Symbol 3
1
2 2
4 1
Description: Design/function Symbol Pushbutton with normally open function Function With a pushbutton, the selected switching position is only retained for as long as it is actuated. The pushbutton shown performs the function of a normally open contact. In the case of a normally open contact, the circuit is interrupted in the normal position of the pushbutton, i.e. in the unactuated state. Actuation of the switching stem causes the circuit to be closed and current to flow to the consuming device. Once the switching stem is released, the pushbutton returns to the normal position as a result of the spring force, thereby interrupting the circuit. Symbol Detent switch with normally closed contact Function In the case of a detent switch both switching positions are mechanically locked. A switching position is therefore always retained until the switch is re-actuated. The detent switch shown performs the function of a normally closed contact. With a normally closed contact the circuit is closed in the normal position of the detent switch due to the spring force. Actuation of the detent switch causes the circuit to be interrupted and renewed actuation closes the circuit again. Symbol Pushbutton with changeover function Function In the case of this pushbutton, the selected switching position is retained only for as long as this is actuated. The pushbutton shown performs the function of a changeover switch, where the functions of a normally closed and normally open contact are combined in one device. A switching action causes one circuit to be closed and another circuit to be opened. Both circuits are briefly interrupted during switching.
© Festo Didactic GmbH & Co. KG • 541090
C-7
Exercise 1: Realising a sorting device Solutions
Exercise 1: Realising a sorting device Name:
Date:
Fundamentals: Mode of operation of different valve types
Sheet 6 of 7
Electrically actuated directional control valves are switched with the help of solenoids and can basically be divided into two groups: • Spring return valves • Double solenoid valves – Describe how these two groups differ with regard to function and behaviour in the event of a power failure. Valve type Spring return valve
Mode of operation The actuated switching position is maintained only for as long as current flows through the solenoid coil. The normal position is clearly defined by the return spring. In the event of a power failure the valve switches to the normal position via the spring and this may trigger dangerous machine movements, e.g. causes the piston rod of a pneumatic cylinder to move into the initial position and release the clamping of a workpiece.
Double-solenoid valve
Switching of the valve merely requires a brief signal; due to the static friction, the last assumed switching position is retained even in the de-energised state. All solenoid coils are de-energised in the normal position and the normal position cannot be clearly defined. In the event of a power failure, the valve retains its last switching position; no dangerous movements are triggered, e.g. the piston rod of a pneumatic cylinder maintains its operating position and retains a workpiece.
C-8
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Exercise 1: Realising a sorting device Solutions
Exercise 1: Realising a sorting device Name:
Date:
Fundamentals: Port designations of valves
Sheet 7 of 7
In order to prevent incorrect tubing of directional control valves, valve ports (working and pilot lines) are identified to ISO 5599 3, both on the valve itself and in the circuit diagram. – Describe the meaning or function of the designations below. Designation 3
Working line, exhaust port
12
Pilot line, with pilot actuated or pneumatically actuated directional control valves; Function on actuation: Connection of supply port 1 and working port 2
10
© Festo Didactic GmbH & Co. KG • 541090
Meaning or function
Pilot line, with pilot actuated or pneumatically actuated directional control valves; Function on actuation: Closing of supply port 1
C-9
Exercise 1: Realising a sorting device Solutions
Exercise 1: Realising a sorting device Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 1 of 2
– Design the pneumatic and electrical circuit diagrams for the sorting device. 1A1
1V2
2
1 1V1 1M1
2
1
3 0Z2
0Z1
1 2
3
Pneumatic circuit diagram
C-10
© Festo Didactic GmbH & Co. KG • 541090
Exercise 1: Realising a sorting device Solutions
Exercise 1: Realising a sorting device Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 2 of 2
+24 V
1
13 S1 14
1M1
0V
Electrical circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
C-11
Exercise 1: Realising a sorting device Solutions
Exercise 1: Realising a sorting device Name:
Date:
Process description
Sheet 1 of 1
Initial position The cylinder is in the retracted end position. Steps 1-2 Actuation of pushbutton S1 (normally open contact), causes the solenoid coil 1M1 of the 3/2-way solenoid valve 1V1 to be energised. The valve 1V1 reverses and cylinder 1A1 advances. Steps 2-3 As soon as pushbutton S1(normally open contact) is no longer actuated, the coil 1M1 is de-energised, the valve 1V1 is returned into the initial position via the return spring, the cylinder 1A1 is exhausted and the spring returns the cylinder into the retracted end position.
C-12
© Festo Didactic GmbH & Co. KG • 541090
Exercise 1: Realising a sorting device Solutions
Exercise 1: Realising a sorting device Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Compile the equipment list by entering the required equipment in the table below. Quantity
Description
1
Cylinder, single-acting
1
One-way flow control valve
1
3/2-way solenoid valve, normally closed
1
Pushbutton (normally open contact)
1
Manifold
1
Start-up valve with filter control valve
1
Compressed air supply
1
Power supply unit 24 V DC
Equipment list
© Festo Didactic GmbH & Co. KG • 541090
C-13
Exercise 1: Realising a sorting device Solutions
C-14
© Festo Didactic GmbH & Co. KG • 541090
Exercise 2: Realising a shut-off device Solutions
Exercise 2: Realising a shut-off device Name:
Date:
Fundamentals: Comparison of directly actuated and pilot actuated valves
Sheet 1 of 5
Differentiation is made between directly actuated and pilot actuated directional control valves with regard to the type of actuation. – Compare these two valve types and describe the respective advantages and disadvantages. Directly actuated valve
Pilot actuated valve
Flow is releases to the consuming device via
Flow to the consuming device is switched via the
the armature of the solenoid. In order to obtain
main stage. The valve piston is moved via an air
a sufficient cross section of opening, a
duct from pressure port 1.
comparably large armature is required. This
This only requires a low flow so that a
consequently requires a powerful return spring
comparatively small armature with minimal
and the solenoid to generate a high force. It is
actuating force can be used. A minimum supply
therefore of a large design with high power consumption.
pressure is required in order to actuate the piston against the spring force. Compared to a directly actuated valve, the solenoid can be configured in a small design and the power consumption and heat emission is thus reduced.
© Festo Didactic GmbH & Co. KG • 541090
C-15
Exercise 2: Realising a shut-off device Solutions
Exercise 2: Realising a shut-off device Name:
Date:
Fundamentals: Comparison of directly actuated and pilot actuated valves
Sheet 2 of 5
In order to prevent incorrect tubing up of directional control valves, valve ports (working and pilot lines) are identified in accordance with ISO 5599-3, both on the valve itself and in the circuit diagram. – Describe the meaning and function of the designations below Designation 4
Working line, working port
14
Power line, with pilot actuated or pneumatically actuated directional control valves Function on actuation: Connection of supply port 1 and working port 4
82/84
C-16
Meaning, function
Pilot line, with pilot actuated or pneumatically actuated directional control valves Function on actuation: Auxiliary pilot air exhausting
© Festo Didactic GmbH & Co. KG • 541090
Exercise 2: Realising a shut-off device Solutions
Exercise 2: Realising a shut-off device Name:
Date:
Fundamentals: Mode of operation of a solenoid valve
Sheet 3 of 5
A valve symbol provides information regarding the function of the valve, i.e. the number of ports, switching positions and type of actuation, but not about the constructional design. – Describe the mode of operation of the directional control valve shown. 4
2
1M1 5
1
3
Description: Mode of operation of directional control valve Pilot actuated 5/2-way solenoid valve, with manual override, with spring return Mode of operation: In the normal position, the piston is positioned at the lefthand stop, the ports 1 (supply port) and 2 (working port), as well as the ports 4 (working port) and 5 (exhaust port) are connected. If the solenoid coil is energised, the valve piston moves up to the righthand stop. In this position, ports 1 and 4 as well as 2 and 3 (exhaust port) are connected (the designation of the internal line of the pilot control is 14; function on actuation: Connection of supply port 1 and working port 4). If the solenoid is de-energised, the valve piston switches back into the normal position due to the spring force and the pilot air is exhausted. In the de-energised state the valve can be switched by means of a manual override.
© Festo Didactic GmbH & Co. KG • 541090
C-17
Exercise 2: Realising a shut-off device Solutions
Exercise 2: Realising a shut-off device Name:
Date:
Fundamentals: IP classification
Sheet 4 of 5
Depending on the installation and ambient conditions, electrical equipment is protected by means of a housing or cover. The required protection class against dust, humidity and foreign objects is to be identified. Protection class IP 65 is shown on a valve. – Describe the meaning of this classification. Description: IP 65 classification In accordance with DIN-VDE 470-1, the protection classification code is composed of the two letters IP (for “International Protection”) and two digits. The first digit indicates the scope of protection against the ingress of dust or foreign objects and the second digit the scope of protection against the penetration of humidity or water. Protection class IP 65 therefore means protection against the ingress of dust . (i.e. complete protection against contact with energised or internally moving parts, protection against the ingress of dust) and hose-water (i.e. strong jets of water aimed from any direction against the housing/enclosure must not have any harmful effect).
C-18
© Festo Didactic GmbH & Co. KG • 541090
Exercise 2: Realising a shut-off device Solutions
Exercise 2: Realising a shut-off device Name:
Date:
Fundamentals: Symbols of pneumatic cylinders
Sheet 5 of 5
Piston rod cylinder with linear action can be divided into two groups: • Single-acting cylinders • Double-acting cylinders – Describe the meaning of the cylinder symbols shown. Symbol 1
Symbol 2
Description: Symbolic representation Symbol 1 Double-acting multi-position cylinder; reversal via alternating supply of compressed air. By series connecting two cylinders of identical piston diameter and different stroke length, it is possible to approach three positions. The third position can be approached directly or via the second intermediate position from the first position. However, to do so the subsequent cylinder stroke must always be greater than the previous stroke. With the return stroke, an intermediate position is only possible with the appropriate actuation (3 working positions). The shorter stroke length is half of the longer one. Symbol 2 Double-acting cylinder, reversal via alternating supply of compressed air, adjustable end position cushioning (2 working positions) Cushioning is used in the end position if large loads are to be moved by a cylinder. Prior to reaching the end position, a cushioning piston interrupts the direct exhaust path of air to atmosphere. The restricted exhaust air causes the piston speed to be reduced during the last part of the stroke travel.
© Festo Didactic GmbH & Co. KG • 541090
C-19
Exercise 2: Realising a shut-off device Solutions
Exercise 2: Realising a shut-off device Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 1 of 1
– Design the pneumatic and electrical circuit diagrams for the shut-off device. 1A1
1V2
1V1
1
1
2
2
4
1V3
2
1M1 5
1
3
Pneumatic circuit diagram
+24 V
1
13 S1 14
1M1
0V
Electrical circuit diagram
C-20
© Festo Didactic GmbH & Co. KG • 541090
Exercise 2: Realising a shut-off device Solutions
Exercise 2: Realising a shut-off device Name:
Date:
Process description
Sheet 1 of 1
Initial position The cylinder is in the retracted end position. Steps 1-2 Actuation of pushbutton S1(normally open contact) causes the solenoid coil 1M1 of the 5/2-way solenoid valve 1V1 to be energised and the valve 1V1 to reverse. The piston side of cylinder 1A1 is now filled with compressed air whilst the piston rod side is exhausted. Cylinder 1A1 advances. Steps 2-3 As soon as pushbutton S1 (normally open contact) is no longer actuated, the coil 1M1 is de-energised and the valve 1V1 is returned to the initial position again via the return spring. The piston side of cylinder 1A1 is exhausted whilst the piston rod side is filled with compressed air. The cylinder returns into the retracted end position.
© Festo Didactic GmbH & Co. KG • 541090
C-21
Exercise 2: Realising a shut-off device Solutions
Exercise 2: Realising a shut-off device Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Compile the equipment list by entering the required equipment in the table below. Quantity
Description
1
Cylinder, double-acting
2
One-way flow control valve
1
5/2-way solenoid valve
1
Pushbutton (normally open contact)
1
Manifold
1
Start-up valve with filter control valve
1
Compressed air supply
1
Power supply unit 24 V DC
Equipment list
C-22
© Festo Didactic GmbH & Co. KG • 541090
Exercise 3: Realising a lid press Solutions
Exercise 3: Realising a lid press Name:
Date:
Fundamentals: Mode of operation of relays
Sheet 1 of 4
Relays form part of the components of the electrical signal control section. The main components are: • Coil with core • Coil winding • Contact set • Return spring • Armature • Terminal lugs The illustration below represents a sectional view of a relay. – Allocate the component designations. 2
3
1 4 5
A1 A2
4 2
7
1
6
The relay consists of (1) Coil with core (2) Return spring (3) Coil winding (4) Armature (5) Contact set (6) Terminal lugs (7) Terminal lugs
© Festo Didactic GmbH & Co. KG • 541090
C-23
Exercise 3: Realising a lid press Solutions
Exercise 3: Realising a lid press Name:
Date:
Fundamentals: Design and mode of operation of relays
Sheet 2 of 4
– Describe the mode of operation of a relay. Description: Mode of operation of a relay A relay is an electromagnetically operated switch. An electromagnetic field is created if voltage is applied at the coil of the solenoid, which causes the movable armature to be attracted to the coil core. The armature acts on the relay contacts which, depending on configuration either open or close. If the current flow through the coil is interrupted, a spring causes the armature to return into the initial position.
C-24
© Festo Didactic GmbH & Co. KG • 541090
Exercise 3: Realising a lid press Solutions
Exercise 3: Realising a lid press Name:
Date:
Fundamentals: Design and mode of operation of relays
Sheet 3 of 4
One or several contacts can be switched by a relay coil. Depending on the required function, a relay with normally open, normally closed or changeover contact(s) is used. Additional designs of electromagnetically operated switches are for instance the remanence relay, time relay with switch-on delay and the contactor. – Describe the design and contact line-up of the relays shown. Description: Design/contact line-up Design: Relay with two normally closed contacts and two normally open contacts
Symbol
A1
13
23
31
41
14
24
32
42
12 14
22 24
32 34
42 44
11
21
31
41
Function: If the relay coil is energised, two of the four contacts are opened and two contacts are closed.
A2
Design: Relay with four changeover contacts Function: If the relay coil is energised, up to four
A1
current paths are opened or closed via the four relay contacts. High flexibility, wide range of different contact combinations possible.
© Festo Didactic GmbH & Co. KG • 541090
A2
C-25
Exercise 3: Realising a lid press Solutions
Exercise 3: Realising a list press Name:
Date:
Fundamentals: Design and mode of operation of relays
Sheet 4 of 4
– Name possible applications of relays in electrical or electropneumatic control systems. Description: Possible applications
C-26
•
Signal multiplication
•
Voltage or current amplification
•
Delaying or converting of signals
•
Logic operations of information
•
Isolation of control and primary circuits
•
Isolation of DC and AC circuits in purely electrical control systems
© Festo Didactic GmbH & Co. KG • 541090
Exercise 3: Realising a lid press Solutions
Exercise 3: Realising a lid press Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 1 of 2
– Design the pneumatic and electrical circuit diagrams for the lid press. 1A1
1V2
1V1
1
1
2
2
4
1V3
2
1M1 5
1
3
Pneumatic circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
C-27
Exercise 3: Realising a lid press Solutions
Exercise 3: Realising a lid press Name:
Date:
Completing the pneumatic and electrical circuit diagrams
Sheet 2 of 2
+24 V
1
2
13
12
14
K1
S1
11
14
A1 K1
1M1 A2
0V 11
12 14 .2
21
22 24
31
32 34
41
42 44
Electrical circuit diagram
C-28
© Festo Didactic GmbH & Co. KG • 541090
Exercise 3: Realising a lid press Solutions
Exercise 3: Realising a lid press Name:
Date:
Process description
Sheet 1 of 1
Initial position Cylinder 1A1 is in the retracted end position. Steps 1-2 Actuation of pushbutton S1 (normally open contact) causes the relay K1 to be energised, the changeover contact K1 (connected in the form of a normally open contact) also closed and the solenoid coil 1M1 of the 5/2-way valve 1V1 is energised. The valve 1V1 reverses and causes the rear chamber of cylinder 1A1 to be filled with compressed air whilst the front chamber if exhausted. Cylinder 1A1 advances. Steps 2-3 As soon as pushbutton S1 (normally open contact) is no longer actuated, relay K1 is de-energised and the changeover contact K1(connected in the form of a normally open contact) opens. This causes the coil 1M1 to be de-energised and the valve 1V1 to be returned into the initial position via the return spring. The rear chamber of cylinder 1A1 is exhausted whilst the front chamber is filled with compressed air. the cylinder returns into the retracted end position.
© Festo Didactic GmbH & Co. KG • 541090
C-29
Exercise 3: Realising a lid press Solutions
Exercise 3: Realising a lid press Name:
Date:
Completing the pneumatic and electrical circuit diagrams, alternative solution
Sheet 1 of 2
Indirect actuation does of course function equally with a 3/2-way solenoid valve and single-acting cylinder. 1A1
1V2
2
1 1V1 1M1
2
1
3
Pneumatic circuit diagram
C-30
© Festo Didactic GmbH & Co. KG • 541090
Exercise 3: Realising a lid press Solutions
Exercise 3: Realising a lid press Name:
Date:
Completing the pneumatic and electrical circuit diagrams, alternative solution
Sheet 2 of 2
+24 V
1
2
13
12
14
K1
S1
11
14
A1 K1
1M1 A2
0V 11
12 14 .2
21
22 24
31
32 34
41
42 44
Electrical circuit diagram
© Festo Didactic GmbH & Co. KG • 541090
C-31
Exercise 3: Realising a lid press Solutions
Exercise 3: Realising a lid press Name:
Date:
Compiling the equipment list
Sheet 1 of 1
Apart from the circuit diagram, comprehensive project documentation also requires an equipment list. – Create the equipment list by entering the required equipment in the table below. Quantity
Designation
1
Cylinder, double-acting
2
One-way flow control valve
1
5/2-way solenoid valve
1
Pushbutton (normally open)
1
Relay
1
Manifold
1
Start-up valve with filter control valve
1
Compressed air supply
1
Power supply unit 24 V DC
Equipment list
C-32
© Festo Didactic GmbH & Co. KG • 541090
Exercise 4: Realising the operation of a hinged lid Solutions
Exercise 4: Realising the operation of a hinged lid Name:
Date:
Fundamentals: Converting solenoid valves
Sheet 1 of 3
In industrial practice there are numerous different requirements placed on a valve. If a valve with the desired characteristics is not available, it is often possible to use a valve with a different number of ports to obtain the required function. The table below lists a selection of directional control valves frequently in use in industrial applications. – Describe the valve types shown. – Designate all the solenoid valves that can be replaced by using a 5/2-way solenoid valve of the type shown. – If conversion measures need to be taken in order to obtain the desired function, then please describe thee. Note By the term „conversion measures“ we understand the simplest of conversions, such as the closing of working ports 2 or 4 using a blanking plug. 4
2
14 1M1 5
1
Symbol
Description: Valve type
12 1M1
2
Pilot actuated, spring return
1
2/2-way solenoid valve, with manual override
2 12 1M1
1
1 4
14 1M1
1
Replacement possible
3
3/2-way solenoid valve, normally closed, with manual override
Replacement possible, no conversion required?
X
Replacement possible, conversion by closing working port 2 using a blanking plug
X
Replacement possible, conversion by closing working port 4 using a blanking plug
Pilot actuated, spring return 3 2
3
3/2-way solenoid valve, normally open, with manual override Pilot-actuated, spring return 4/2-way solenoid valve, with manual override
© Festo Didactic GmbH & Co. KG • 541090
Description: Necessary conversions
X
Pilot actuated, spring return
2 10 1M1
3
Replacement possible, no conversion required X
C-33
Exercise 4: Realising the operation of a hinged lid Solutions
Exercise 4: Realising the operation of hinged lid Name:
Date:
Fundamentals: Selecting solenoid valves
Sheet 2 of 3
The choice of a valve is made according to the following criteria: • Problem definition, • Required behaviour in the event of a power failure, • Lowest possible overall costs The following choice of valves is available for the actuation of a single-acting cylinder: • A pilot actuated, spring return 3/2-way solenoid valve with manual override • A pilot actuated, spring return 5/2-way solenoid valve with manual override – Make your choice and explain your reasons for this. Note Apart from the costs of the actual valve, the above mentioned overall costs of a valve also include the costs for installation, maintenance and storage of replacement parts. Valve type
Reason
Pilot actuated, spring
As can be seen from question 1, the 5/2-way solenoid valve has a broad
return 5/2-way
spectrum of possible applications. In practice this means that only one valve
solenoid valve with manual override
type is required for different requirements or applications. This in turn means a considerable cost reduction thanks to more alternatives when it comes to the procurement of the valve and storage of replacement parts. The maintenance of different valves entails considerable higher expenditure compared to maintaining a single valve type. A 3/2-way valve can only actuate single-acting cylinders whereas a 5/2-way valve can actuate singleacting and double-acting cylinders. This is why the choice should be a 5/2way solenoid valve. The fact that the costs of a 3/2-way solenoid valve are usually 5 % below that of a 5/2-way double solenoid valve is immaterial in view of the above mentioned advantages.
C-34
© Festo Didactic GmbH & Co. KG • 541090
Exercise 4: Realising the operation of a hinged lid Solutions
Exercise 4: Realising the operation of a hinged lid Name:
Date:
Fundamentals
Sheet 3 of 3
Triggering the advance of the cylinder piston rod is to be possible using two pushbuttons S1 and S2. If at least one of the two pushbuttons is actuated, the valve coil 1M1 is energised, the solenoid valve 1V1 switches into the actuated position and the piston rod advances. If both pushbuttons are released, the valve switches into the initial position and the piston rod retracts. – Create the appropriate function table and the logic symbol. Note 0 means: Pushbutton not actuated, i.e. piston rod does not advance 1 means: Pushbutton actuated, i.e. piston rod advances S1
S2
1M1
1V1
0 (not actuated)
0 (not actuated)
0 (not actuated)
0 (not actuated)
0 (not actuated)
1 (actuated)
1 (actuated)
1 (actuated)
1 (actuated)
0 (not actuated)
1 (actuated)
1 (actuated)
1 (actuated)
1 (actuated)
1 (actuated)
1 (actuated)
Function table
S1
Relay K1 is not energised => Relay contact in
relay K1, current path 2
current path 8 (changeover contact, connected in the form of normally open contact) does not switch => Piston rod of cylinder 2A1 does not move into the forward end position (remains retracted), sensor 2B2 is not actuated => Piston rod of cylinder 1A1 remains advanced since 1M2 is not actuated.
Break in signal wire of
Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Piston rod of cylinder2A1 moves into the
sensor 2B2, current path 4
forward end position, sensor 2B2 is actuated => Relay K2 is not energised => Relay contact in current path 7
Break in supply line of relay
Current path 5 is not closed, relay K3 is not energised, no reaction in response to start signal => Piston rod
K3, current path 5
of cylinder 1A1 and piston rod of cylinder 2A1 remain retracted.
Break in supply line of relay
Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Piston rod of cylinder 2A1 moves into the
contact 14 (relay K2), current path 7
forward end position, sensor 2B2 is actuated => Relay K2 is energised, relay contact in current path 7
Break in earthing wire 2M1, current path 8
Piston rod of cylinder 1A1 advances => Sensor 1B2 is actuated => Relay K1is energised, relay contact in
(changeover contact, connected in the form of a normally open contact) does not switch => Piston rod of 1A1 and piston rod of cylinder 2A1 remain advanced.
(changeover contact, connected in the form of a normally open contact) switches, but valve coil 1M2 is not energised due to cable break => Piston rod of cylinder 1A1 and piston rod of cylinder 2A1 remain advanced.
current path 8 (changeover contact, connected in the form of a normally open contact) switches, but valve coil 2M1 is not energised due to cable break => Piston rod of cylinder 2A1 remains retracted, piston rod of 1A1 remains advanced.
C-104
© Festo Didactic GmbH & Co. KG • 541090
Exercise 12: Eliminating a fault on the pallet loading station Solutions
Exercise 12: Eliminating a fault in the pallet loading station Name:
Date:
List of faults
Sheet 1 of 1
Simulation of faults
Cause of fault
Effect of fault
Displace sensor 1B2 on cylinder
Sensor 1B2 at cylinder
Piston rod of cylinder 1A1 advances, sensor 1B2 is briefly actuated =>
1A1 in the retracted end position direction
1A1 maladjusted
Piston rod of cylinder 2A1 does not move up to the forward end position,
Remove sensor 1B2 signal line or
Cable break in signal line
Piston rod of cylinder 1A1 advances => No sensor signal, i.e. sensor 1B2
displace sensor at forward end position
of sensor 1B2, or sensor maladjusted
is not actuated => Piston rod of cylinder 2A1 remains retracted, piston rod of cylinder 1A1 remains advanced.
Remove sensor 2B2 signal line or
Cable break in signal line
Piston rod of cylinder 1A1 advances, sensor 1B2 is actuated => Piston
displace sensor at forward end position
of sensor 2B2, or sensor maladjusted
rod of cylinder 2A1 advances into the forward end position, no sensor
Interrupt current path 2 (e.g.
Cable break in earthing
earthing wire of relay K1, signal
wire of 2M1, K1 or supply
Piston rod of cylinder 1A1 advances => Piston rod of cylinder 2A1 remains retracted since current path 2 or current path 8 is interrupted.
line or current path 8, e.g. supply
lines of relay contact 14/11 (relay K1)
lines of relay contact 14 or relay
sensor 2B2 is not actuated => Piston rod of cylinder 1A1 remains advanced since 1M2 is not actuated.
signal, i.e. sensor 2B2 is not actuated => Piston rod of cylinder 1A1 and piston rod of cylinder 2A1 remain advanced.
contact 11 (relay K1), remove earthing wire of 2M1 Interrupt earthing wire of relay K2,
Cable break in earthing
current path 4 or current path 7,
wire of 1M2, K2 or supply
or remove relay K2 or supply lines
lines of relay contact 14/11 (relay K2)
of relay contact 14 or relay contact
Piston rod of cylinder 1A1 and piston rod of cylinder 2A1 advance and remain in the forward end position.
11 (relays K2), earthing wire of 1M2 Interrupt earthing wire of relay K3,
Cable break in earthing
No reaction to start signal => Piston rod of cylinder 1A1 and piston rod of
current path 5 or current path 6
wire 1M1, K3 or supply
cylinder 2A1 remain retracted.
Remove 1M1 or K3 or supply line of relay contact 14 at K3
line of relay contact 14 at K3
© Festo Didactic GmbH & Co. KG • 541090
C-105
Exercise 12: Eliminating a fault on the pallet loading station Solutions
Exercise 12: Eliminating a fault in the pallet loading station Name:
Date:
Notes for the trainer
Sheet 1 of 1
Notes for the trainer It is advisable to deal with this exercise after solving exercise 11 of TP 201, since the correct configuration of circuit will then be available and in tested form. The fault can be directly built into the circuit by the trainer (see list of simulation of faults). It is important to make sure that trainees proceed systematically during fault finding. Alternative If the circuit of exercise 11 is not available fully assembled, it is also possible to carry out the fault finding theoretically: • The trainer explains the fault („cylinder 1A1 advances, the circuit then comes to a stop.“) • Trainees then localise the fault with the help of the function chart. • Trainees draw up a list of potential causes of faults and describe how they proceed during the fault finding (where do you need to measure, what needs to be checked).
C-106
© Festo Didactic GmbH & Co. KG • 541090
Part D – Appendix
Organiser __________________________________________________________ D-2 Assembly technology ________________________________________________ D-3 Plastic tubing_______________________________________________________ D-4 Data sheets
Single-acting cylinder _____________________________________________ 152887 Double-acting cylinder ____________________________________________ 152888 Manifold________________________________________________________ 152896 Relay, 3 off______________________________________________________ 162241 Signal input plate, electrical ________________________________________ 162242 Proximity sensor, optical __________________________________________ 178577 Limit switch, electrical, actuated from the left__________________________ 183322 Limit switch, electrical, actuated from the right ________________________ 183345 Pressure sensor with display _______________________________________ 539757 One-way flow control valve_________________________________________ 539773 2 x 3/2-way solenoid valve with LED, normally closed ___________________ 539776 5/2-way solenoid valve with LED ____________________________________ 539777 5/2-way double solenoid valve with LED______________________________ 539778 Start-up valve with filter control valve ________________________________ 540691 Proximity sensor, electronic, with cylinder mounting ____________________ 540695
© Festo Didactic GmbH & Co. KG • 541090
D-1
Organiser
Equipment set in the organiser All components of the equipment set for the technology package TP201 are stored in an organiser within a Systainer. The organiser also serves as a drawer insert for use in conjunction with our range of laboratory furniture.
D-2
© Festo Didactic GmbH & Co. KG • 541090
Assembly technology
The components of the equipment set are intended for assembly on the Festo Didactic profile plate, which consists of 14parallel T-slots, 50 mm apart. Three variants are available for the assembly of equipment on the profile plate: Variant A A latching system, without auxiliary means, clamping mechanism using a lever and spring, adjustable in the direction of the slot, for lightweight non-loadable components. Variant B A rotary system, without auxiliary means, knurled nut with locking disc and T-head bolts, vertical or horizontal alignment, for medium weight loadable components . Variant C A screw system, with auxiliary means, socket head screw with T-head bolt, vertical and horizontal alignment, for heavy loadable components and equipment which is rarely released from the profile plate. The proven ER units on plug-in board can be attached to the profile plate with adapters. In the case of variant A, a slide is engaged in the T-slot of the profile plate. The slide is pre-tensioned by means of a spring and, by pressing the blue lever, is pulled back whereby the component can be removed from or attached to the profile plate. Components are aligned along the slot and can be moved in the direction of the slot. With variant B, components are attached to the profile plate by means of a T-head bolt and blue knurled nut. A locking disc serves to fix the device in position, which can be secured in any 90° direction. Devices can thus be mounted on the profile plate either lengthwise or diagonally to the slot. Once the desired locking disc position is set, the device is mounted on the profile plate. By turning the knurled nut in a clockwise direction, the T-head bolt is turned in the slot by 90° owing to thread friction. The component is pressed against the profile plate by further turning the knurled nut.
© Festo Didactic GmbH & Co. KG • 541090
D-3
Variant C is used for heavy or similar devices, screwed on to the profile plate only once or very seldom. Components are attached by means of socket head screws with internal hex and T-head bolts. The time-tested ER units on a plug-in board with locating pins in a 50 mm grid can be mounted on the profile plate using adapters. A black plastic adapter is required for each locating pin. The adapters are plugged into the T-slot, positioned at intervals of 50 mm and secured by means of a 90° turn. The locating pins of the ER unit are plugged into the adapter holes.
Plastic tubing
The polyurethane tubing is particularly flexible and kink resistant. Technical data Pneumatics Colour
Silver metallic
Outer diameterr
4 mm
Inner diameter
2.6 mm
Minimum bending radius within temperature range of -35 to +60°C
17 mm
Maximum operating pressure within temperature range of -35 to +30°C
10 bar (1000 kPa)
within temperature range of +30 to +40°C within temperature range of +40 to +60°C
9 bar (900 kPa) 7 bar (700 kPa)
Subject to change
D-4
© Festo Didactic GmbH & Co. KG • 541090
152887 Single-acting cylinder
Design
The single-acting cylinder with trip cam and push-in fitting is mounted on a plastic retainer. The unit is mounted on the profile plate via quick release detent system with two blue trip grip nuts (mounting alternative "B").
Function
The piston rod of the single-acting cylinder moves into the forward end position through the supply of compressed air. When the compressed air is switched off, the piston is returned to the retracted end position via a return spring. The magnetic field of a permanent magnet, which is attached to the cylinder piston, actuates the proximity switches.
Technical data
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated)
Design
Piston cylinder
Operating pressure max.
1000 kPa (10 bar)
Piston diameter
20 mm
Max. stroke length
50 mm
Thrust at 600 kPa (6 bar)
139 N
Spring return force min.
13.6 N
Connection
QS-G1/8-4 fittings for plastic tubing PUN 4 x 0.75
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/1
© Festo Didactic GmbH & Co. KG, 07/2005
152888 Double-acting cylinder
Design
The double-acting cylinder with trip cam and push-in fittings is mounted on a plastic retainer. The unit is mounted on the profile plate via a quick release detent system with two triple grip nuts (mounting alternative "B").
Function
The piston rod of the double-acting cylinder is reversed by means of alternating supply of compressed air. End position cushioning at both ends prevents a sudden impact of the piston on the cylinder housing. The end position cushioning can be adjusted by means of two regulating screws. The magnetic field of a permanent magnet attached to the cylinder piston actuates the proximity switches.
Technical data
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated)
Design
Piston cylinder
Operating pressure max.
1000 kPa (10 bar)
Piston diameter
20 mm
Max. stroke length
100 mm
Thrust at 600 kPa (6 bar)
189 N
Return force at 600 kPa (6 bar)
158 N
Connection
QS-G1/8-4 fittings for plastic tubing PUN 4 x 0.75
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/1
© Festo Didactic GmbH & Co. KG, 07/2005
152896 Manifold
Design
The manifold with eight self-sealing push-in fittings is screwed on to a universal plate. The unit is mounted on the profile plate via a quick release detent system with blue lever (mounting alternative "A").
Function
The manifold with a common P-supply enables a control system to be supplied with compressed air eight individual connections.
Technical data
Pneumatic Connection
© Festo Didactic GmbH & Co. KG, 07/2005
1 QS-1/8-6 for plastic tubing PUN 6 x 1 8 QSK-1/8-4 for plastic tubing PUN 4 x 0.75
Subject to change
1/1
© Festo Didactic GmbH & Co. KG, 07/2005
162241 Relay, 3-off
A1
12 14
22 24
32 34
42 44
11
21
31
41
12 14
22 24
32 34
42 44
A2 A1
A2 A1
11
21
31
41
12 14
22 24
32 34
42 44
11
21
31
41
A2
Design
This component consists of three relays with connections and two bus-bars for the power supply. All electrical connections are in the form of 4 mm sockets. The unit can be mounted in a mounting frame or on the profile plate using four plug-in adapters.
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/4
162241 Relay, 3-off
2
3
1 4 5
A1 A2
4 2
7
1
6
Function
The relay consists of a coil with a core (1) and winding (3) with connection lugs (7), an armature (4), a return spring (2) and a contact assembly with four changeover contacts (5) and connection lugs (6). When power is applied to the coil connections, current flows through the winding, creating a magnetic field. The armature is pulled onto the coil core and the contact assembly is actuated. Electrical circuits are opened or closed via this assembly. When the electrical current is removed, the magnetic field collapses and the armature and contact assembly are returned to their original position by a return spring.
Note
The switching status of the relays is indicated by LEDs, which are protected against incorrect polarity. The four changeover contacts of the contact assembly can be used as normally-open contacts (1), normally-closed contacts (2) or changeover contacts (3).
2/4
Subject to change
© Festo Didactic GmbH & Co. KG, 07/2005
162241 Relay, 3-off
+24 V
1
2
13
12
S1
14
K1 11
14
A1 K1
1M1 A2
0V 11
12 14 .2
21
22 24
31
32 34
41
42 44
Example of application: Circuit diagram, electrical
+24 V
1
2
A1
12
+24 V
1
14
2
A1
K1
12
14
K1 A2
Changeover switch connected as normally-open contact
A2
11
11
Changeover switch connected as normally-closed contact
Normally-open contacts, normally-closed contacts: Allocation of contacts on relay plate
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
3/4
162241 Relay, 3-off
Technical data
Electrical Voltage
24 V DC
Contact assembly
4 changeover contacts
Contact rating
Max. 5 A
Contact interrupt rating
Max. 90 W
Pichup time
10 ms
Drop-off time
8 ms
Connections
For 4 mm safety connector plug
Electromagnetic compatibility
4/4
Emitted interference
tested to EN 500 81-1
Noise immunity
tested to EN 500 82-1
Subject to change
© Festo Didactic GmbH & Co. KG, 07/2005
162242 Signal input plate, electrical
13
23
31
41
14
24
32
42
13
23
31
41
14
24
32
42
13
23
31
41
14
24
32
42
Design
This component consists of two illuminated pushbuttons in the form of momentarycontact switches and one illuminated pushbutton in the form of a detented switch. All electrical connections are in the form of 4 mm safety connectors. The unit can be mounted in a mounting frame or on the profile plate using four plug-in adapters.
Function
The illuminated pushbutton in the form of a detented switch consists of a contact assembly with two normally-open contacts and two normally-closed contacts, together with a colourless transparent pushbutton cap with a miniature lamp. The contact assembly is actuated by pressing this cap. Electrical circuits are opened or closed via the contact assembly. When the cap is released, the switching status is maintained. The contact assembly is returned to its initial position by pressing the pushbutton a second time. The illuminated pushbuttons in the form of momentary-contact switches consist of a contact assembly with two normally-open contacts and two normally-closed contacts, together with a colourless transparent pushbutton cap with a miniature lamp. The contact assembly is actuated by pressing this cap. Electrical circuits are opened or closed via the contact assembly. When the cap is released, the contact assembly returns to its initial position.
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/2
162242 Signal input plate, electrical
Note
When power is applied to the connections of the visual indicator, the switching status is displayed by the built-in miniature lamp in the pushbuttons.
+24 V
1
2
13
12
S1
14
K1 11
14
A1 K1
1M1 A2
0V 11
12 14 .2
21
22 24
31
32 34
41
42 44
Example: Circuit diagram, electrical
Technical data
Electrical Voltage
24 V DC
Contact assembly
2 normally-open contacts, 2 normally-closed contacts
Contact rating
Max. 1 A
Power consumption (miniature lamp)
0.48 W
Connections
For 4 mm safety connector plug
Electromagnetic compatibility
2/2
Emitted interference
tested to EN 500 81-1
Noise immunity
tested to EN 500 82-1
Subject to change
© Festo Didactic GmbH & Co. KG, 07/2005
178577 Proximity sensor, optical
Design
The optical proximity sensor with LED and electrical connections is assembled on a polymer assembly base. The electrical connection is effected by means of safety connectors or via a 3-pin plug socket. The unit is mounted on the profile plate via a quick release detent system with blue triple grip nut (mounting alternative “B”).
Function
Optical proximity sensors consist of two main modules, the emitter and the receiver. In the case of diffuse sensor, these are built into one housing. The emitter of the diffuse sensor emits a pulsating, red light which is within the visible spectral range. The object to be detected reflects part of the light emitted. This light is detected by a semiconductor device in the receiver which is also built into the sensor housing and causes a change in the switching status. The object to be detected may be reflective, matt, transparent or opaque. All that is needed is for a sufficiently high proportion of light to be reflected directly or diffusely. The operational switching distance may be varied by means of a potentiometer. The proximity sensor has a PNP output, i.e. the signal line is switched to the positive potential in the switched status. The switch is designed as a normally closed contact. The connection of the load takes place between the signal output of the proximity sensor and the load. The switching status is indicated by a yellow LED. The sensor is protected against polarity reversal, overload and short circuit.
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/2
178577 Proximity sensor, optical
+24V-
B
BN + BK BU
S Note
Technical Data
The correct polarity of the applied voltage is necessary for proper functioning. The connections for the operating voltage are colour coded as follows: red for positive, blue for negative and black for the signal output. The load is connected to the switching output and the negative terminal of the current supply.
Electrical Switching voltage
10 – 30 V DC
Residual ripple
maximum 10%
Nominal switching distance
0 to 100 mm (adjustable)
Switching frequency
maximum 200 Hz
Output function
Normally open contact, positive switching
Output current
maximum 100 mA
Protection class
IP65
Connections
for 4 mm safety connector plug or 3-pin socket
Cable
with 4 mm safety connector plug
Electromagnetic compatibility
2/2
Eitted interference
tested to EN 500 81-1
Noise immunity
tested to EN 500 82-1
Subject to change
© Festo Didactic GmbH & Co. KG, 07/2005
183322 Limit switch, electrical, actuated from the left
2
4 1
The two electrical limit switches, order no. 183322 for actuation from the left and order no. 183345 for actuation from the right, have the same symbol in the circuit diagram.
Design
A microswitch with roller lever and electrical connections is installed in a plastic housing. The electrical connection is effected by means of safety connectors or via a 3-pin plug socket. The component is mounted on the profile plate using the rotary system by means of two blue grip nuts (mounting variant “B”).
Function
This electrical limit switch consists of a mechanically-actuated microswitch. It is actuated when the roller lever is pressed, for example by the trip cam of a cylinder. The switch contacts are used to open or close a circuit. The microswitch returns to its original position when the roller lever is released.
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/2
183322 Limit switch, electrical, actuated from the left
Note
Technical data
The microswitch can be connected up to act as a normally-open contact (1), normally-closed contact (2) or changeover contact (3). In cases where piston speeds are high, the limit switch should be actuated by the trip cam of a cylinder only in the specified direction. The limit switch must not be actuated from the front.
Electrical Design
Mechanically-actuated electrical microswitch in limit-switch housing
Voltage
24 V DC
Contact rating
Max. 5 A
Switching frequency
Max. 200 Hz
Reproducible switching accuracy
0.2 mm
Switch travel
2.7 mm
Actuation force
5N
Connection
For 4 mm safety connector plug or 3-pin plug socket
Electromagnetic compatibility
2/2
Emitted interference
tested to EN 500 81-1
Noise immunity
tested to EN 500 82-1
Subject to change
© Festo Didactic GmbH & Co. KG, 07/2005
183345 Limit switch, electrical, actuated from the right
2
4 1
The two electrical limit switches, order no. 183322 for actuation from the left and order no. 183345 for actuation from the right, have the same symbol in the circuit diagram.
Design
A microswitch with roller lever and electrical connections is installed in a plastic housing. The electrical connection is effected by means of safety connectors or via a 3-pin plug socket. The component is mounted on the profile plate using the rotary system by means of two blue grip nuts (mounting variant “B”).
Function
This electrical limit switch consists of a mechanically-actuated microswitch. It is actuated when the roller lever is pressed, for example by the trip cam of a cylinder. The switch contacts are used to open or close a circuit. The microswitch returns to its original position when the roller lever is released.
© Festo Didactic GmbH & Co. KG, 09/2005
Subject to change
1/2
183345 Limit switch, electrical, actuated from the right
Note
Technical data
The microswitch can be connected up to act as a normally-open contact (1), normally-closed contact (2) or changeover contact (3). In cases where piston speeds are high, the limit switch should be actuated by the trip cam of a cylinder only in the specified direction. The limit switch must not be actuated from the front.
Electrical Design
Mechanically-actuated electrical microswitch in limit-switch housing
Voltage
24 V DC
Contact rating
Max. 5 A
Switching frequency
Max. 200 Hz
Reproducible switching accuracy
0.2 mm
Switch travel
2.7 mm
Actuation force
5N
Connection
For 4 mm safety connector plug or 3-pin plug socket
Electromagnetic compatibility
2/2
Emitted interference
tested to EN 500 81-1
Noise immunity
tested to EN 500 82-1
Subject to change
© Festo Didactic GmbH & Co. KG, 09/2005
539757 Pressure sensor with display
p
Design
The pressure sensor with display is screwed onto the adapter plate plate. The unit is attached via the grid system with the blue lever (assembly variant „A“).
Function
The pressure sensor is a piezoresistive relative pressure transducer with integrated amplifier and built-in temperature compensation. The pressure to be measured is transferred onto a silicone coated piezoresistive element. The signal change generated therein is output as a voltage or switching signal at the connector plug via an intergrated amplifer.
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/2
539757 Pressure sensor with display
+24V-
B
BN p
BK
BU
Note
Technical data
The polarity of the applied voltage is to be observed for the correct functioning of the device. The connections for the operating voltage are to be identified by colour: Red for positive and blue for negative. The signal output is black. The load is to be connected to the switch output and to the negative pole of the power supply.
Electrics Switching voltage
15 – 30V DC
Residual ripple
Max. 10%
Operating pressure
0 to 10 bar (0 to 1000 kPa)
Analogue output
0 to 10 V
Output function
Normally open contact, positive switching
Switching current
Max. 150 mA
Protection class
IP65
Connection
Plug M8x1
Cable
With 4 mm jack plug
Electromagnetic compatibility
2/2
Emitted interference
Tested to EN 500 81-1
Noise immunity
Tested to EN 500 82-1
Subject to change
© Festo Didactic GmbH & Co. KG, 07/2005
539773 One-way flow control valve
1
2
Design
The adjustable one-way flow control valve is screwed into the function plate, incorporating a straight push-in fitting. The unit is slotted into the profile plate via a quick release detent system with a blue lever (mounting alternative “A”).
Function
The one-way flow control valve consists of a combination of a flow control valve and a non-return valve. The non-return valve blocks the flow of air in one direction, whereby the air flows via the flow control valve. The throttle cross section is adjustable by means of a knurled screw. The setting can be fixed by means of a knurled nut. Two arrows indicate the direction of flow control on the housing. In the opposite direction, the air flow is unrestricted via the non-return valve.
Technical Data
Pneumatic Medium
Compressed air, filtered, (lubricated or unlubricated)
Design
One-way flow control valve
Pressure range
20 to 1000 kPa (0.2 to 10 bar)
Standard nominal flow rate
in throttled direction:
0 – 110 l/min
free flow direction:
110 l/min (Throttle open) 65 l/min (Throttle closed)
Connection
© Festo Didactic GmbH & Co. KG, 06/2005
QSM-M5-4 for plastic tubing PUN 4 x 0.75
Subject to change
1/1
© Festo Didactic GmbH & Co. KG, 06/2005
539776 2 x 3/2-way solenoid valve with LED, normally closed
2 1M1
1
3
1M1
Design
This 3/2-way single solenoid valve with push-in fittings is attached to a function plate which is equipped with a P port and silencer. The two electrical connections are equipped with safety connectors. The unit is mounted on the profile plate using a quick release detent system with a blue lever (mounting alternative "A").
Function
The solenoid valve is reversed when voltage is applied to the solenoid coil (1 2) and brought back into its initial position (1 0) by a return spring when the signal is removed. The switching status is displayed via an LED in the terminal housing. The valve is equipped with a manual override.
Note
The solenoid coil is characterised by very low power consumption and low heat generation. The electrical connection incorporates protection against incorrect polarity for the LED and a protective circuit.
© Festo Didactic GmbH & Co. KG, 09/2005
Subject to change
1/2
539776 2 x 3/2-way solenoid valve with LED, normally closed
Technical Data
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated)
Design
Spool valve, pilot-actuated, with return spring
Pressure range
300 to 800 kPa (3 to 8 bar)
Switching time at 600 kPa (6 bar)
On: 20 ms Off: 33 ms
Standard nominal flow rate
1000 l/min
Connection
QS 3 for plastic tubing PUN 4 x 0.75
Electrical
2/2
Voltage
24 V DC
Duty cycle
100 %
Protection class
IP65
Connection
M8x1 central plug, cable with socket and 4 mm safety plugs
Subject to change
© Festo Didactic GmbH & Co. KG, 09/2005
539777 5/2-way single solenoid valve with LED
4
2
1M1 5
1
3
1M1
Design
This 5/2-way single solenoid valve with push-in fittings is bolted onto a function plate which is equipped with a P port and silencer. The two electrical connections are equipped with safety connectors. The unit is mounted on the profile plate using a snap-lock system with a blue lever (mounting variant "A").
Function
The solenoid valve is reversed when voltage is applied to the solenoid coil (1 4) and brought back into its initial position (1 2) by a return spring when the signal is removed. The switching status is shown by an LED in the terminal housing. The valve is equipped with a manual override.
Note
The solenoid coil is characterised by very low power consumption and low heat generation. The electrical connection incorporates protection against incorrect polarity for the LED and a protective circuit.
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/2
539777 5/2-way single solenoid valve with LED
Technical Data
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated)
Design
Spool valve, pilot-actuated, with return spring
Pressure range
300 to 800 kPa (3 to 8 bar)
Switching time at 600 kPa (6 bar)
On: 25 ms OFF: 40 ms
Standard nominal flow rate
1000 l/min
Connection
QS-1/8-4-I fittings for plastic tubing PUN 4 x 0.75
Electrical
2/2
Voltage
24 V DC
Duty cycle
100 %
Protection class
IP65
Connection
M8x1 central plug, cable with socket and 4 mm safety plugs
Subject to change
© Festo Didactic GmbH & Co. KG, 07/2005
539778 5/2-way double solenoid valve with LED
4
2
1M1
1M2 5
1M1
1
3
1M2
Design
This 5/2-way double solenoid valve with push-in fitting is bolted onto a function plate which is equipped with a P port and silencer. The four electrical connections are equipped with safety connectors. The unit is mounted on the profile plate using a snap-lock system with a blue lever (mounting variant "A").
Function
The double solenoid valve is reversed when voltage is applied to a solenoid coil and remains in this switching position after the signal is removed until an opposed signal is applied. The presence of switching signals is shown by the LEDs in the terminal housings. The valve is equipped with a manual override.
Note
The solenoid coil is characterised by very low power consumption and low heat generation. The electrical connections incorporate protection against incorrect polarity for the LEDs and protective circuits.
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/2
539778 5/2-way double solenoid valve with LED
Technical Data
Pneumatic Medium
Compressed air, filtered (lubricated or unlubricated)
Design
Spool valve, pilot-actuated
Pressure range
300 to 800 kPa (3 to 8 bar)
Switching time at 600 kPa (6 bar)
15 ms
Standard nominal flow rate
1000 l/min
Connection
3 QS-1/8-4-I fittings for plastic tubing PUN 4 x 0.75
Electrical
2/2
Voltage
24 V DC
Duty cycle
100 %
Protection class
IP65
Connection
M8x1 central plug, cable with socket and 4 mm safety plugs
Subject to change
© Festo Didactic GmbH & Co. KG, 07/2005
540691 Start-up valve with filter control valve
1 2
3 1 2
3
Design
The filter regulator with pressure gauge, on/off valve, push-in fitting and quick coupling plug is mounted on a swivelling retainer. The filter bowl is fitted with a metal bowl guard. The unit is mounted on the profile plate by means of cheese head screws and T-head nuts (mounting alternative “C”). Attached is a quick coupling socket with threaded bush and connector nut for plastic tubing PUN 6 x 1.
Function
The filter with water separator cleans the compressed air of dirt, pipe scale, rust and condensate. The pressure regulator adjusts the compressed air supplied to the set operating pressure and compensates for pressure fluctuations. An arrow on the housing indicates the direction of flow. The filter bowl is fitted with a filter drain screw. The pressure gauge shows the preset pressure. The on/off valve exhausts the entire control. The 3/2-way valve is actuated via the blue sliding sleeve.
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/2
540691 Start-up valve with filter control valve
Note
Technical Data
When constructing a circuit, please ensure that the filter regulator is installed in the vertical position. The pressure regulator is fitted with an adjusting knob, which can be turned to set the required pressure. By sliding the adjusting knob towards the housing, the setting can be locked.
Pneumatic Medium
Compressed air
Design
Sintered filter with water separator, diaphragm control valve
Assembly position
Vertical ±5°
Standard nominal flow rate *
110 l/min
Upstream pressure
100 to 1000 kPa (1 to 10 bar)
Operating pressure
50 to 700 kPa (0.5 to 7 bar)
Connection
Coupling plug for coupling socket G1/8 QS push-in fitting for plastic tubing PUN 6 x 1
* Upstream pressure: 1000 kPa (10 bar), Operating pressure: 600 kPa (6 bar), Differential pressure: 100 kPa (1 bar).
2/2
Subject to change
© Festo Didactic GmbH & Co. KG, 07/2005
540695 Proximity sensor, electronic, with cylinder mounting
Design
The proximity sensor consists of the sensor, mounting kit and cable . The cable is equipped with a socket and three jack plugs.
Function
This proximity sensor emits an electrical signal when approaching a magnetic field (e.g. permanent magnet on a cylinder piston). The electrical connections are moulded into the cable. The switching status is indicated via an LED. The yellow LED is illuminated when actuated.
+24V-
B
BN + BK BU
Note
The polarity of the applied voltage is to be observed for the correct functioning of the device. The wires inside the socket cable must therefore be allocated by colour: Red (BN) for positive, blue (BU) for negative and black (BK) for the signal output. In this case, the load (relay) is connected to the sensor and to the negative pole. The switch is protected against reverse polarity but not against short circuit.
© Festo Didactic GmbH & Co. KG, 07/2005
Subject to change
1/2
540695 Proximity sensor, electronic, with cylinder mounting
Technical data
Electrics Switching voltage
10 to 30 V DC
Switching current
Max. 200 mA
Switching accuracy
±0.1 mm
Switching time
On: 0.5 ms Off: 0.5 ms
Connection
M 8x1 plug socket for socket with cable
Cable
With 4 mm jack plug
Electromagnetic compatibility
2/2
Emitted interference
Tested to EN 500 81-1
Noise immunity
Tested to EN 500 82-1
Subject to change
© Festo Didactic GmbH & Co. KG, 07/2005
